Fire-resistant glazing

Abstract

The fire-resistant glazing comprises a laminate of at least three transparent plies and at least two transparent fire-resistant layers, each fire-resistant layer being an intermediate layer between two plies, with at least one fire-resistant layer comprising a hardened layer and at least one fire-resistant layer comprising a dry layer.

Description

Background Art

[0001] The present invention relates to a fire-resistant glazing having improved fire-resistant performance as compared with conventional specific fire-resistant glazings.

[0002] One type of conventional fire-resistant glazing comprises a laminate of at least two transparent plies and at least one transparent fire-resistant layer, each fire-resistant layer being an intermediate layer between two plies.

[0003] In such a glazing, each transparent ply comprises an annealed glass sheet, and each transparent fire-resistant layer comprises an expandable material that swells or foams (expands) when the glazing is exposed to fire, forming a barrier layer that is resistant to the passage of hot gases and flames, as well as heat conduction and radiation.

[0004] This glazing may include safety glazing in order to provide a fire-resistant glazing having high impact resistance. Usually, safety glazing comprises a laminate having two annealed glass sheets and a transparent plastic film that bonds these glass sheets.

[0005] Alternatively, the fire-resistant glazing may include a heat-strengthened glass sheet or a fully tempered glass sheet in order to provide a fire-resistant glazing having high impact resistance. The heat-strengthened or fully tempered glass sheet is usually an outer sheet of the laminate.

[0006] These fire-resistant glazings are used in a variety of fire-protective glazing systems suitable for various buildings or other locations.

[0007] Examples of fire-resistant glazings include those sold under the trademarks Pyrostop® and Pyrodur®, and are also used in various doors, wall partitions, sloping horizontal roofs and floors, and even building facades.

[0008] Examples of fire-resistant glazing using heat-strengthened or fully tempered glass include those marketed under the trademarks Pyrostop® and Pyrodur®, and are used in ship bulkheads, walls, and even within the hull of vessels.

[0009] One known method for manufacturing these fire-resistant glazings is the "cast-in-place (CIP)" method. The CIP method is described, for example, in International Publication No. 2008 / 053247 (incorporated herein by reference).

[0010] In this method, an aqueous solution containing an expandable material precursor is injected into a cavity formed by an assembly comprising two opposing glass plates and a transparent, nearly peripheral spacer bar placed between the glass plates.

[0011] Subsequently, the cavity is completely sealed by completing the spacer bar, and the aqueous solution is cured within the sealed cavity to form a refractory layer of expandable material between the glass plates.

[0012] Curing is performed by irradiating the aqueous solution with visible or UV light for a predetermined period of time, or by heating the assembly to a predetermined temperature.

[0013] The assembly may include additional glass plates and periphery seals that allow the same aqueous solution to cure in multiple cavities simultaneously.

[0014] Fire-resistant glazing produced by this method may, in particular, consist of 1-cell, 2-cell, or 3-cell CIP glazing (the number of cells corresponds to the number of fire-resistant layers).

[0015] Please note that in this method as well, safety glazing, heat-tempered glass sheets, or fully tempered glass sheets can be used in place of one or more annealed glass sheets.

[0016] Another known method for producing fire-resistant glazing is the "Pour-Aid Drying (PAD)" process. The PAD process is described, for example, in International Patent Publication 2007 / 118887 (which is incorporated herein by reference).

[0017] In this method, an aqueous suspension containing an alkali metal silicate is poured onto the surface of a first glass plate and spread substantially across the entire surface. The suspension is heated on the first glass plate under strictly controlled conditions until it dries and forms a solid layer of expandable material.

[0018] Subsequently, the glass surface of the second glass plate, which has a solid expandable layer, is laminated onto the solid expandable layer of the first glass plate.

[0019] The laminate is completed by applying a peripheral sealing tape that covers almost the entire surface in the thickness direction of the laminate.

[0020] This method may also include sequentially stacking additional glass plates having the same drying and expanding layer before covering them with a cap glass plate.

[0021] In this method as well, it should be noted that safety glazing or heat-tempered glass sheets, or fully tempered glass sheets, can be used in place of one or more glass sheets, especially cap glass sheets.

[0022] These fire-resistant glazing systems, including fire-resistant glazing, must meet, and do meet, the fire resistance performance classifications of the relevant building, rail, and / or maritime authorities, but there is always a need for further improvements in fire resistance.

[0023] The inventors have observed that fire-resistant glazing produced by the CIP method tends to have different fire resistance performance compared to fire-resistant glazing produced by the PAD process. This is because the expansive material used in the CIP method is typically different from that used in the PAD process.

[0024] For example, fire-resistant glazing manufactured by the CIP method may have better EI performance compared to fire-resistant glazing manufactured by the PAD process.

[0025] Furthermore, fire-resistant glazing manufactured by the PAD process tends to have better EW performance compared to fire-resistant glazing manufactured by the CIP method.

[0026] Therefore, when considering a fire protection glazing system, designers often have to choose either good EI fire resistance or good EW performance.

[0027] An object of the present invention is to improve this situation by providing a fire-resistant glazing comprising a fire-resistant layer consisting of a cured layer and a dried layer.

[0028] Therefore, in a first aspect, the present invention provides a fire-resistant glazing comprising a laminate of at least three transparent plies and at least two transparent fire-resistant layers, each fire-resistant layer being an intermediate layer between two plies, at least one fire-resistant layer comprising a cured layer, and at least one fire-resistant layer comprising a dried layer.

[0029] It should be noted that the reference to the cured layer in this specification is a reference to a layer cured without drying. The reference to the dried layer is a reference to a layer obtained by drying an aqueous liquid or suspension to form a solid layer.

[0030] The transparent ply may particularly comprise a glass plate formed from inorganic glass or organic glass. The glass plate may have any suitable geometric shape, but is preferably linear or circular.

[0031] Suitable inorganic glasses include alkali silicate glass, alkali borosilicate glass, alkali aluminosilicate glass, and ceramic glass such as that sold by Nippon Electric Glass Co., Ltd. under the trademark Firelite (registered trademark).

[0032] However, preferably, the inorganic glass is soda-lime glass, such as float glass. In this case, the tin side of the float glass may have a silicon oxynitride or other coating to suppress blooming on the glass surface.

[0033] In these embodiments, one or more glass plates may consist of heat-tempered glass or fully tempered glass, and the remainder may consist of annealed glass.

[0034] For example, one or each of the outer glass plates may be made of heat-tempered glass or fully tempered glass, and each inner glass plate may be made of annealed glass.

[0035] Suitable organic glass includes plastic materials such as polycarbonate and poly(methyl methacrylate), which are sold under multiple trademark names, including Perspex®.

[0036] One or each of the outer plies of the fire-resistant glazing may have one or more anti-reflective coatings, antimicrobial coatings, antiviral coatings, easy-clean coatings, or self-cleaning coatings on their outer surface.

[0037] Furthermore, or alternatively, one or each of the inner plies of the fire-resistant glazing may have a low-emissivity coating on its outward-facing and / or inward-facing surfaces.

[0038] Please note that float glass sheets with anti-reflective coatings are sold under the brand name Optiview®. Float glass sheets with self-cleaning coatings are sold under the brand names Activ® and SaniTise®. Float glass sheets with low-emissivity coatings are sold under the brand name K Glass®.

[0039] A suitable cured or dried refractory layer comprises any material known to those skilled in the art, whether or not it is expansive.

[0040] The cured layer may, in particular, comprise an organic hydrogel, an inorganic hydrogel, or a hybrid inorganic-organic hydrogel.

[0041] Suitable organic hydrogels include hydrogels based on polyacrylate or polyacrylamide in water, such as the hydrogel described in International Patent Publication No. 2014 / 190444.

[0042] Suitable inorganic hydrogels include silica sols or aerogels, or hydrogels containing alkali metal silicates and silica sols in water.

[0043] Suitable hybrid inorganic-organic hydrogels include polyacrylate-silicate hydrogels in water, as described, for example, by Mastalska-Poplawska, J. et al. in Polymer Engineering and Science, 2019, 59(6), 1279-1287.

[0044] The dry layer may comprise, in particular, a hydrogel based on silica sol or aerogel, or an inorganic hydrogel such as a hydrogel containing alkali metal silicate and silica sol in water.

[0045] In some embodiments, both the cured layer and the dried layer comprise an inorganic hydrogel.

[0046] Inorganic hydrogels may be water glass based on alkali metal silicates, water glass based on silica sols, or water glass based on alkali metal silicates and silica sols in water.

[0047] Preferably, the cured layer comprises a first inorganic hydrogel, and the dried layer comprises a second inorganic hydrogel different from the first inorganic hydrogel. In this case, the cured layer may have a different chemical composition (e.g., different alkali metal or water or additive content) compared to the dried layer.

[0048] In a preferred embodiment, the cured layer comprises potassium water glass, and the dried layer comprises sodium water glass.

[0049] Suitable potassium water glass includes those commonly formed on a ply by the CIP method.

[0050] Preferred potassium silicate (SiO2:K2O) water glasses are described in International Patent Publication No. 2008 / 053247. These water glasses comprise an organic silica sol and / or aqueous silica sol (at least 30% by weight as solids), with a molar ratio of silicon dioxide to potassium oxide of at least 4.0:1, preferably at least 4.5:1, and have a relatively low water content (35-43% by weight).

[0051] Suitable sodium water glass includes sodium silicate (SiO2:Na2O) water glass with a weight ratio of at least 1.6:1.0 for SiO2:Na2O, preferably 2.0:1.0 to 6.0:1.0, for example 4.0:1.0.

[0052] Other suitable sodium water glasses include those based on the sodium silicate described above, in which sodium ions are partially substituted with potassium and / or lithium ions.

[0053] The molar ratio of sodium ions to potassium and / or lithium ions in these water glasses can be at least 2:1, and in particular can be in the range of 1.4:1.0 to 2.5:1.0.

[0054] Water glass may, in particular, comprise a mixture of sodium silicate and potassium silicate, in which case the molar ratio of sodium ions to potassium ions is at least 4.0:1.0.

[0055] These sodium aqueous glasses are generally formed on plies by "implant drying (PAD)" of an aqueous precursor solution comprising an alkali metal silicate and, optionally, a polyol, such as glycerol or diethylene glycol, acrylate, polysaccharide, cellulose or starch, or collagen such as gelatin, as a coolant.

[0056] Most preferably, the inorganic (or other) hydrogel comprises at least 20% by weight of water.

[0057] In some embodiments, the cured layer has a higher moisture content than the dry layer, for example, 5% to 30% by weight, for example, 5%, 10%, or 15% by weight higher.

[0058] The hardened layer may have a moisture content of 35-50% by weight, for example, 40-45% by weight, and the dry layer may have a moisture content of 20-35% by weight, for example, 22-28% by weight or 30% by weight.

[0059] The order of the hardened and dried layers within the fire-resistant glazing is not particularly limited.

[0060] In one embodiment, the top fire-resistant layer is a hardened layer, and the remaining fire-resistant layer is a dried layer.

[0061] In another embodiment, the intermediate or intervening fire-resistant layer is a hardened layer, and the remaining fire-resistant layer is a dry layer.

[0062] In yet another embodiment, the top and bottom fire-resistant layers are hardened layers, and the remaining fire-resistant layers are dry layers.

[0063] Fire-resistant glazing may consist of, for example, 4 to 15 transparent plies and 3 to 14 fire-resistant layers, where the top fire-resistant layer is a hardened layer and the other fire-resistant layers may be dry layers.

[0064] This comprises 4 to 15 transparent plies and 3 to 14 fire-resistant layers, where the intermediate or intervening fire-resistant layers are hardened layers, and the other fire-resistant layers may be dry layers.

[0065] This comprises 4 to 15 transparent plies and 3 to 14 fire-resistant layers, with the top and bottom fire-resistant layers being hardened layers and the other fire-resistant layers being dry layers.

[0066] In other embodiments, the intermediate or intervening fire-resistant layer is a dry layer, and the remaining fire-resistant layer is a hardened layer.

[0067] Fire-resistant glazing may consist of, for example, 4 to 15 transparent plies and 3 to 14 fire-resistant layers, where the intermediate or intervening fire-resistant layers are dry layers and the remaining fire-resistant layers are hardened layers.

[0068] The hardened layer and the dried layer may have thicknesses that correspond to the typical thickness of the refractory layer provided in the refractory glazing by the CIP method and the PAD process, respectively.

[0069] In some embodiments, each cured layer has the same thickness, and each dried layer has the same thickness, but its thickness is different from that of the cured layers.

[0070] In other embodiments, the cured layers have different thicknesses from each other, and each dried layer has the same thickness, which is different from the thickness of at least one of the cured layers.

[0071] In yet another embodiment, the dry layers have different thicknesses from each other, and each cured layer has the same thickness, which is different from the thickness of at least one of the dry layers.

[0072] In some embodiments, the thickness of each cured layer may be greater or less than the thickness of each dried layer.

[0073] In either case, each fire-resistant layer may have a thickness of 0.50 mm to 22.00 mm, for example, in the range of 1.00 mm to 6.00 mm, and preferably in the range of 1.20 mm to 4.00 mm.

[0074] The plies may have thicknesses similar to those used in the CIP and PAD processes. These thicknesses can vary in a similar manner to those described above for the refractory layer thickness.

[0075] In certain embodiments, each outer ply has a thickness that is 0.2 mm to 10.00 mm greater than the thickness of at least one inner ply or each inner ply, for example, 0.5 mm, 1.00 mm, 1.50 mm, 3.00 mm, or 5.0 mm greater. Preferably, each outer glass plate has a greater thickness than each inner ply.

[0076] In some embodiments, the fire-resistant glazing comprises at least four plies, at least two fire-resistant layers, and cured layers, for example, two or three cured layers, and an epoxy resin, polyacrylate, or polyurethane, selected to improve the impact resistance of the glazing.

[0077] Preferably, though not required, the cured layer comprises at least one flame retardant additive.

[0078] In these embodiments, the thickness of the resin or polymer layer may range from 0.1 mm to 10 mm, and may be, for example, less than 5 mm or less than 1 mm.

[0079] The fire-resistant glazing does not need to differ in any other respect from the description above. Other cured and dried layers may also include water glass as described above.

[0080] It should be noted that by including a cured layer comprising epoxy resin, polyacrylate, or polyurethane, impact resistance equivalent to that obtained when conventional safety glazing is included can be achieved.

[0081] However, fire-resistant glazing may, as an alternative or additional measure, incorporate such safety glazing.

[0082] In this case, the fire-resistant glazing comprises at least four transparent plies, at least two transparent fire-resistant layers, and a transparent adhesive plastic film, with the fire-resistant layers and the plastic film each being intermediate layers between two plies.

[0083] When a cured layer comprising epoxy resin, polyacrylate, or polyurethane is present, the fire-resistant glazing comprises at least five transparent plies, at least two fire-resistant layers, and a transparent adhesive plastic film, as well as a cured layer comprising epoxy resin, polyacrylate, or polyurethane.

[0084] The adhesive plastic film may be selected from those known to those skilled in the art. It may comprise one or more layers of polyvinyl acetal, particularly polyvinyl butyral, ionomer, polyethylene vinyl acetate, polyurethane, polycarbonate, or acrylic resin.

[0085] Adhesive plastic films can have thicknesses ranging from 0.1 mm to 10.0 mm, for example, 0.38 mm or 0.76 mm. Suitable films for providing such plastic interlayers are known and commercially available.

[0086] The position of the cured layer or plastic film comprising epoxy resin, polyacrylate, or polyurethane within the fire-resistant glazing is not particularly limited. The resin or polymer layer or plastic film may be the outermost or innermost intermediate layer. In particular, the resin or polymer layer or plastic film may be interposed between the cured layer and the dry layer, or between cured layers, or between dry layers.

[0087] The fire-resistant glazing may further comprise a peripheral “edge” sealing tape that covers at least a portion or substantially the entire surface in the thickness direction of the laminate. When the sealing tape covers the entire surface in the thickness direction of the laminate, it may also overlap the respective edge portions of the upper and lower surfaces of the laminate.

[0088] In certain embodiments, the edge sealing tape covers a portion of the thickness-direction surface of the laminate corresponding to the dry layer and its adjacent plies. Naturally, the edge sealing tape may cover multiple such portions.

[0089] In these embodiments, it should be noted that the portion of the surface in the thickness direction corresponding to the cured layer is sealed by a peripheral spacer bar and, if necessary, a peripheral sealing bead.

[0090] In other embodiments, namely those corresponding to cut laminates, the edge sealing tape covers substantially the entire thickness-direction surface of the laminate.

[0091] In alternative embodiments corresponding to similarly cut laminates, the fire-resistant glazing includes a peripheral sealing configuration that extends substantially over the entire thickness-direction surface of the laminate and overlaps the edges of the upper and lower surfaces of the laminate.

[0092] The sealing configuration may, in particular, include a U-frame and, optionally, a thermoplastic sealant for adhesively sealing the U-frame to the thickness-direction surface and edge portions of the laminate.

[0093] The U-frame may be made of a malleable metal such as aluminum. Alternatively, it may be made of an elastic polymer material that can be used with or without a thermoplastic sealant.

[0094] The fire-resistant glazing according to the present invention can achieve EW30 performance when tested in accordance with EN1634-1(2014).

[0095] Alternatively, the fire-resistant glazing may achieve EI30 performance when tested according to EN1634-1(2014).

[0096] This means that, in particular, when tested according to EN1634-1(2014), it may achieve EI60, EI90, EI120, or EI190, and at least one of EW60, EW90, EW120, or EW190 when tested according to EN1634-1(2014).

[0097] The fire-resistant glazing according to the present invention may conform to A2-s1,d1 or higher as determined according to EN13501-2(2016).

[0098] The fire-resistant glazing may, alternatively or additionally, conform to A0, A15, A30, A60, B0, or B15 as measured according to the International Maritime Organization standard IMO A.754(18).

[0099] Furthermore, the fire-resistant glazing may conform to A1-15, A1-30, A2-15, or A2-30 as measured according to the European standard (railway vehicles) EN45545-3.

[0100] In a second embodiment, the present invention is (i) The steps of preparing a first laminate and a second laminate, each comprising at least two plies and at least one fire-resistant layer, wherein each fire-resistant layer is an intermediate layer between the two plies and is a dry layer, (ii) A step of preparing a third laminate by curing a refractory layer precursor solution between the first laminate and the second laminate to form a cured layer, The present invention provides a method for manufacturing fire-resistant glazing, including the method described above.

[0101] This method may, in particular, include preparing the first and second laminates by a PAD process and preparing the third laminate by a CIP method.

[0102] In this case, the preparation of the first laminate and the second laminate may include forming a dry layer on the first ply and overlapping the first fire-resistant layer with the second ply.

[0103] Alternatively, a dry layer can be formed on multiple first plies, and these plies can be stacked with second plies so that each dry layer becomes an intermediate layer between the two plies.

[0104] This method may further include providing edge sealing tape on each thickness-direction surface of the first laminate and the second laminate.

[0105] The method may further include assembling a first laminate and a second laminate with spacers positioned near the periphery, creating a void between the opposing surfaces of the first and second parts, filling the void with a curable precursor solution, completing a periphery seal to seal the void, and curing the precursor solution within the sealed void to form a cured layer.

[0106] Curing can be performed by irradiating the CIP assembly with visible light or UV light at room temperature. Alternatively, it can be performed by heating the CIP assembly to a temperature that does not cause "activation" of the dry layer, preferably 120°C or lower.

[0107] This method may further include providing a secondary sealant on the peripheral spacer bar of the third laminate.

[0108] In some embodiments, where thermally tempered or fully tempered glass is included, the first and second laminates are prepared as oversized “semi-finished products.” These semi-finished products can be cut by a manufacturer performing the CIP method or according to their orders.

[0109] Therefore, the method may further include cutting the first and / or second laminates to desired sizes before preparing the third laminate.

[0110] Alternatively or in addition, the method may include cutting the third laminate to a desired size.

[0111] In either case, the method may further include providing an edge sealing tape or a peripheral sealing configuration on the thickness-direction surface of the cut laminate.

[0112] Cutting can be done, for example, by sawing with a mechanical saw, especially using a commercially available water-cooled rotary saw.

[0113] It should be noted that the cutting of the third laminate is advantageous in terms of fire resistance compared to conventional CIP fire glazing because the hardened layer functions substantially across the entire width of the fire glazing.

[0114] Embodiments in this aspect of the present invention will become clear from the embodiments of the first aspect. In particular, note that each ply may comprise a glass plate, each drying layer may comprise sodium water glass as described above, and each hardened layer may comprise potassium water glass.

[0115] In a third embodiment, the present invention is (i) to prepare a first laminate comprising at least two plies and at least one fire-resistant layer, wherein the fire-resistant layer is an intermediate layer between the two plies and is a dry layer, (ii) A refractory layer precursor solution is cured between the first laminate and an additional ply to form a cured layer, thereby preparing the second laminate. The present invention provides a method for manufacturing fire-resistant glazing, including the method described above.

[0116] This method may, in particular, include preparing a first laminate by a PAD process and preparing a second laminate by a CIP method.

[0117] This method may, in particular, include preparing a second laminate by curing a precursor solution between a first laminate and two additional plies to form two cured layers.

[0118] Curing can be performed by irradiating the CIP assembly with visible light or UV light at room temperature. Alternatively, it can be performed by heating the CIP assembly to a temperature that does not cause "activation" of the dry layer, preferably 120°C or lower.

[0119] In some embodiments, if heat-tempered or fully tempered glass is not provided, the first laminate is prepared as an oversized semi-finished product. This semi-finished product can be cut by a manufacturer performing the CIP method or according to their orders.

[0120] Therefore, the method may further include cutting the first laminate to a desired size before preparing the third laminate.

[0121] Alternatively or in addition, the method may include cutting the second laminate to a desired size.

[0122] In either case, the method may further include providing an edge sealing tape or a peripheral sealing configuration on the thickness-direction surface of the third laminate.

[0123] Embodiments in this aspect of the present invention will become clear from the embodiments of the first aspect. In particular, note that each ply may comprise a glass plate, each drying layer may comprise sodium water glass as described above, and each hardened layer may comprise potassium water glass.

[0124] In a fourth embodiment, the present invention is (i) Prepare a first laminate comprising at least two plies and at least one fire-resistant layer, wherein each fire-resistant layer is an intermediate layer and a hardened layer between the two plies, (ii) Preparing a second laminate by drying the refractory layer precursor solution on at least one ply to form a dry layer, (iii) Preparing a third laminate by pressing the first laminate onto the dry layer of the second laminate, The present invention provides a method for manufacturing fire-resistant glazing, including the application of fire-resistant glazing.

[0125] This method may include preparing the first laminate by the CIP method and preparing the second and third laminates using the PAD process.

[0126] This method may include, in particular, preparing a second laminate by drying a precursor solution on multiple plies, and stacking these plies so that each dried layer becomes an intermediate layer between two plies.

[0127] In some embodiments, if not comprising heat-tempered or fully tempered glass, the first laminate is prepared as a semi-finished product. This semi-finished product can be cut by a manufacturer performing the PAD process or according to their orders.

[0128] The method may further include providing an edge sealing tape or a peripheral sealing configuration on part or substantially the entire surface in the thickness direction of the third laminate.

[0129] Alternatively, the method may include cutting the third laminate to a desired size and providing an edge sealing tape or peripheral sealing configuration on the thickness-direction surface of the third laminate.

[0130] Embodiments in this aspect of the present invention will become clear from the embodiments of the first aspect. In particular, note that each ply may comprise a glass plate, each drying layer may comprise sodium water glass as described above, and each hardened layer may comprise potassium water glass.

[0131] This method may include drying a refractory layer precursor solution on a CIP cell containing a hardened layer. In this case, the drying is carried out at a temperature that does not cause "activation" of the hardened layer, preferably at a temperature of 120°C or lower.

[0132] In a fifth embodiment, the present invention is (i) Prepare a first laminate comprising at least two plies and at least one fire-resistant layer, wherein each fire-resistant layer is an intermediate layer and a hardened layer between the two plies, (ii) Prepare a second laminate comprising at least two plies and at least one fire-resistant layer, wherein each fire-resistant layer is an intermediate layer and a dry layer between the two plies, (iii) Preparing a third laminate by laminating the first laminate together with a plastic film onto the second laminate, The present invention provides a method for manufacturing fire-resistant glazing, including the method described above.

[0133] This method may, in particular, include preparing a first laminate using the CIP method and preparing a second laminate using the PAD process.

[0134] Laminating the first laminate onto the second laminate may involve, for example, placing a plastic film such as a PVB film between the first and second laminates and heating it at a pressure and temperature that does not cause "activation" of the dry and cured layers, for example, at 1 atmosphere and a temperature of 120°C or less.

[0135] This lamination may, in particular, involve heating the polyvinyl butyral film between the first laminate and the second laminate to a temperature of 120°C or less for at least 5 hours under a pressure of 1.2 bar.

[0136] The method may further include cutting the third laminate to a desired size and providing edge sealing tape or a peripheral sealing configuration on the thickness-direction surface of the third laminate.

[0137] Embodiments in this aspect of the present invention will become clear from the embodiments of the first aspect. In particular, note that each ply may comprise a glass plate, each drying layer may comprise sodium water glass as described above, and each hardened layer may comprise potassium water glass.

[0138] Note that in this method, curing in the absence of a dry layer and drying in the absence of a cured layer may be carried out at temperatures typical of the CIP method or PAD process, depending on the case.

[0139] In a sixth embodiment, the present invention provides a product for a fire protection system comprising fire-resistant glazing according to any of the first to fifth embodiments.

[0140] This product may be used as a fixed glazing, or for partial or full surface use on fire doors, walls, roofs, floors, bulkheads, or inside vehicles.

[0141] Alternatively, this product could be a semi-finished product intended to be used in combination with other products to provide security equipment.

[0142] Embodiments in this aspect of the present invention will become clear from the embodiments of the first aspect. In particular, note that each ply may comprise a glass plate, each drying layer may comprise sodium water glass as described above, and each hardened layer may comprise potassium water glass.

[0143] In a seventh embodiment, the present invention provides a fire protection system including fire-resistant glazing according to the first embodiment.

[0144] This fire protection system may, in particular, include double or triple insulated glazing units (IGUs) in which the fire-resistant glazing is separated by gaps containing air or inert gas.

[0145] The IGU may be a triple glazing unit in which a first fire-resistant glazing having three plies and two hardened layers is positioned between two second fire-resistant glazings having two plies and one dry layer.

[0146] Alternatively, the IGU may be a double glazing unit combining a fire-resistant glazing having four plies and three fire-resistant layers with a fire-resistant glazing having four plies, two fire-resistant layers and a plastic film.

[0147] The gap between adjacent fire-resistant glazings may be provided, for example, by a sealing configuration including a peripheral spacer bar. The gap may be divided into compartments, for example, by supports provided between opposing surfaces of the fire-resistant glazings.

[0148] Embodiments in this aspect of the present invention will become clear from the embodiments of the first aspect. In particular, note that each ply may comprise a glass plate, each drying layer may comprise sodium water glass as described above, and each hardened layer may comprise potassium water glass.

[0149] The present invention will be described in more detail below with reference to examples that do not limit the present invention and the surface of the attached figures. [Brief explanation of the drawing]

[0150] [Figure 1] This is a schematic diagram showing a method for manufacturing fire-resistant glazing according to one embodiment of the present invention. [Figure 2] This is a schematic diagram showing a method for manufacturing fire-resistant glazing according to another embodiment of the present invention. [Figure 3] This is a schematic diagram showing a method for manufacturing fire-resistant glazing according to yet another embodiment of the present invention. [Figure 4] This is a schematic diagram showing a method for manufacturing fire-resistant glazing according to yet another embodiment of the present invention. [Figure 5a] These are cross-sectional views of fire-resistant glazing according to several other embodiments of the present invention. [Figure 5b] These are cross-sectional views of fire-resistant glazing according to several other embodiments of the present invention. [Figure 5c] These are cross-sectional views of fire-resistant glazing according to several other embodiments of the present invention. [Figure 5d] These are cross-sectional views of fire-resistant glazing according to several other embodiments of the present invention. [Figure 6] This is a flow diagram showing an overview of the manufacturing method for the aforementioned fire-resistant glazing. [Figure 7]This is a cross-sectional view of a portion of a fire-resistant glazing including a sealing configuration according to one embodiment of the present invention. [Modes for carrying out the invention]

[0151] Figure 1 shows an overview of a method for manufacturing fire-resistant glazing according to one embodiment of the present invention.

[0152] As shown in the figure, this method utilizes a first PAD glass 10 comprising two rectangular glass plates 11 separated by sodium water glass 12, and a second PAD glass also comprising two rectangular glass plates 11 separated by sodium water glass 12.

[0153] The first and second PAD glass 10 are obtained by drying a layer of sodium water glass 12 on a first glass plate 11, placing the second glass plate 11 on top of the dried layer 12, and adhering edge sealing tape (not shown) to the thickness-direction surface of the PAD glass.

[0154] This method includes assembling the first and second PAD glass 10 together with a spacer bar 13 positioned near the periphery, and creating a cavity (not shown) between the opposing surfaces of the first and second PAD glass 10.

[0155] The method further includes introducing a potassium water glass precursor solution into the cavity, sealing the cavity by completing the spacer bar 13, and curing the precursor solution into potassium water glass 14 within the sealed cavity by heating without activating the sodium water glass layer 12 in the PAD glass 10.

[0156] When the spacer bar 13 is positioned inside the glass plate 11, this method allows for the provision of a peripheral bead of secondary sealant (not shown) adjacent to the spacer bar.

[0157] The fire-resistant glazing FRG1 obtained in this manner comprises an upper PAD glass 10 and a lower PAD glass 10, which cooperate to define CIP cells within which the peripheral spacer bar 13 is adjacent to or close to the edge of the glass plate 11.

[0158] When the laminate does not include a heat-strengthened or fully surface-strengthened glass plate 11, the laminate may be cut along one or more edges, in which case the edge tape and edge spacer bar 13 (and bead) are removed along the edges.

[0159] In this case, the method further includes cutting the laminate along one or more peripheries and adhering edge sealing tape (not shown) to it, or providing a sealing structure over at least a portion of the surface of the laminate in the thickness direction.

[0160] The fire-resistant glazing FRG2 obtained in this manner comprises an upper PAD glass 10 and a lower PAD glass 10, with a fire-resistant layer 14 between them.

[0161] The sealing configuration of an example of fire-resistant glazing FRG2, shown as 70 in Figure 7, includes an aluminum frame 71 that extends along the periphery of the glazing and overlaps with the edge portion of the outer surface of the glass plate 11.

[0162] Figure 2 shows an overview of a method for manufacturing fire-resistant glazing according to another embodiment of the present invention.

[0163] As shown in the figure, this method utilizes a PAD glass 10 and two additional glass plates 11.

[0164] This method involves assembling the PAD glass 10 and the glass plate 11 together with two spacer bars 13 positioned near the periphery, thereby forming two cavities (not shown) between the opposing surfaces of the PAD glass 10 and the glass plate 11.

[0165] The method further includes introducing a potassium water glass precursor solution into a cavity, completing a spacer bar 13 to seal the cavity, and curing the precursor solution into solid potassium water glass 13 within the sealed cavity by heating in a way that does not activate the sodium water glass layer 12 in the PAD glass 10.

[0166] When the spacer bars 13 are positioned inside the glass plate 11, this method allows for the provision of peripheral beads of secondary sealant (not shown) adjacent to each spacer bar.

[0167] The resulting fire-resistant glazing FRG3 comprises a PAD glass 10 and a glass plate 11, which work together so that a peripheral spacer bar 13 defines a CIP cell adjacent to the edge of the glass plate 11.

[0168] When the laminate does not include a heat-strengthened or fully surface-strengthened glass plate 11, the laminate may be cut along one or more edges, in which case the edge tape and edge spacer bar 13 are removed along the edges.

[0169] In this case, the method further includes cutting the laminate along one or more edges and adhering a peripheral edge tape (not shown), or providing a sealing structure over at least a portion of the edge surface of the laminate.

[0170] The fire-resistant glazing FRG4 obtained in this way comprises a PAD glass 10 sandwiched between two hardened CIP layers.

[0171] It should be noted that the above method can be alternatively cured by irradiating the assembly with a potassium water glass precursor solution using visible and / or UV light.

[0172] Figure 3 shows an overview of a method for manufacturing fire-resistant glazing according to yet another embodiment of the present invention.

[0173] As shown in the figure, this method includes stacking two glass plates 11, each having a dried layer of sodium water glass 12, by pressing the surface of one glass plate against the dried layer 12 of the other, and stacking a CIP cell on top of the remaining dried layer 12.

[0174] This method may further include providing an edge sealing tape (not shown) on the thickness-direction surface of the portion of the laminate corresponding to the PAD glass 10.

[0175] The resulting fire-resistant glazing FRG5 comprises PAD glass 10 and CIP cells, which share a glass plate 11.

[0176] When the laminate does not include a heat-strengthened or fully surface-strengthened glass plate 11, the laminate may be cut along one or more edges, and the edge tape and edge spacer bar 13 may be removed along the edges. In this case, the method further includes cutting the laminate along one or more edges and adhering edge sealing tape (not shown), or providing a sealing structure over at least a portion of the entire edge surface of the laminate.

[0177] The fire-resistant glazing FRG6 obtained in this way has a PAD glass 10 with an upper hardened layer 14.

[0178] Figure 4 shows an overview of a method for manufacturing fire-resistant glazing according to yet another embodiment of the present invention.

[0179] This method involves laminating the PAD glass 10 and the CIP cell 16 with an adhesive polyvinyl acetal film 15 between them by heating, without activating the dry layer 12 or the hardened layer 14.

[0180] The resulting fire-resistant glazing FRG7 comprises PAD glass 10 and CIP cells 16, which are bonded together by a transparent polymer layer 15.

[0181] When the laminate does not include heat-tempered glass or a fully tempered glass plate 11, the laminate may be cut along part or all of its periphery, in which case the edge tape and periphery spacer bar 13 are removed.

[0182] In that case, the method further includes cutting the laminate along part or all of its periphery and adhering an edge sealing tape (not shown) to it, or providing a sealing structure on part or all of the edge surfaces of the laminate.

[0183] The fire-resistant glazing FRG8 obtained in this way also includes a PAD glass 10 with a hardened layer 14.

[0184] The method described above can be applied by using additional CIP cells 10, glass plates 11, spacer bars 13, and adhesive polyvinyl acetal film 15. The additional CIP cells 10 may contain epoxy resin, polyacrylate, or polyurethane instead of potassium water glass.

[0185] Figure 5 shows several fire-resistant glazings obtained by the method described above.

[0186] Figure 5a shows fire-resistant glazing FRG9 obtained by the method shown in Figure 1. The fire-resistant glazing is formed from a first PAD glass 10 having two rectangular glass plates 11 and one layer of sodium water glass drying layer 12, and a second PAD glass 10 having four rectangular glass plates and two layers of sodium water glass drying layer 12. The fire-resistant glazing includes a hardened layer 14 near the center and sealing edge tape (not shown) to prevent water from entering the fire-resistant layer.

[0187] Figure 5b shows the fire-resistant glazing FRG10 obtained by the method shown in Figure 2. The fire-resistant glazing FRG10 is formed from PAD glass 10 having four rectangular glass plates and two sodium water glass drying layers 12. The fire-resistant layer includes a hardened layer 14 at the top and bottom, and also includes edge sealing tape (not shown) to prevent water from entering the fire-resistant layer.

[0188] Figure 5c shows the fire-resistant glazing FRG11 obtained by the method shown in Figure 3. The fire-resistant glazing FRG11 is formed by overlapping a CIP glass, which has two CIP cells formed from safety glass 17 and two glass plates 11, onto a drying layer formed on PAD glass, and by providing edge sealing tape (not shown) to prevent water from entering the fire-resistant layer.

[0189] Figure 5d shows the fire-resistant glazing FRG12 obtained by the method shown in Figure 3. The fire-resistant glazing FRG12 is formed by layering CIP glass, which has two CIP cells, onto a dry layer formed on PAD glass 10 incorporating safety glass 17, and by providing a peripheral edge tape (not shown) to prevent water from entering the fire-resistant layer.

[0190] Figure 6 is a flow diagram summarizing the method described above for manufacturing refractory glazing comprising a hardened layer and a dried layer.

[0191] As shown in the figure, the manufacturing process includes the steps of forming a laminate by a cast-in-place (CIP) method using at least one PAD glass (S1), using a CIP cell as a cap glass in the PAD process (S2), or laminating a PAD cell to a CIP cell with an adhesive plastic film (S3).

[0192] The manufacturing process may or may not further include sealing the thickness-direction surface of the newly formed laminate.

[0193] In some embodiments, the manufacturing process does not require the step of forming one or more CIP cells using one or more PAD glass and sealing the thickness-direction surface of the laminate.

[0194] In other embodiments, the manufacturing process involves forming one or more CIP cells using one or more cut PAD glass and sealing portions of the thickness-direction surface of the laminate corresponding to the cut PAD glass.

[0195] In yet another embodiment, the manufacturing process requires using CIP cells instead of glass plates in the PAD process and sealing the portion of the laminate corresponding to the PAD glass.

[0196] In yet another embodiment, the manufacturing process involves forming one or more CIP cells using one or more PAD glass, cutting the laminate, and sealing the entire surface of the laminate in the thickness direction.

[0197] The present invention provides a combination of a PAD layer and a CIP layer within a fire-resistant glazing. This provides a fire-resistant glazing with superior protective performance compared to fire-resistant glazing having only a CIP layer or only a PAD layer.

[0198] It is particularly advantageous to place the EW-optimized portion corresponding to the dry layer in the outer part of the glazing and the EI-optimized portion corresponding to the hardened layer in the central part of the glazing.

[0199] Furthermore, the present invention offers special advantages with respect to security characteristics that can be achieved by fire-resistant glazing.

[0200] It is possible to use CIP cells containing organic polymers or resins, which can provide fire-resistant glazing with superior impact resistance compared to fire-resistant glazing incorporating safety glass having only a cured or dried layer.

Claims

1. A fire-resistant glazing comprising a laminate of at least three transparent plies and at least two transparent fire-resistant layers, wherein each fire-resistant layer is an intermediate layer between two plies, at least one fire-resistant layer comprises a cured layer, and at least one fire-resistant layer comprises a dried layer.

2. The fire-resistant glazing according to claim 1, wherein each of the hardened layer and the dried layer comprises a hydrogel.

3. The fire-resistant glazing according to claim 1 or claim 2, wherein the cured layer comprises an organic hydrogel or a hybrid organic-inorganic hydrogel, and the dried layer comprises an inorganic hydrogel.

4. The fire-resistant glazing according to claim 1 or 2, wherein the cured layer comprises a first inorganic hydrogel, and the dried layer comprises a second inorganic hydrogel different from the first inorganic hydrogel.

5. The fire-resistant glazing according to claim 4, wherein the hardened layer comprises potassium water glass and the dried layer comprises sodium water glass.

6. The fire-resistant glazing according to any one of claims 1 to 5, wherein the hardened layer has a lower moisture content than the dry layer.

7. A fire-resistant glazing according to any one of claims 1 to 6, comprising a continuous hardened layer and a continuous dried layer.

8. A fire-resistant glazing according to any one of claims 1 to 7, comprising alternating hardened layers and dried layers.

9. The fire-resistant glazing according to any one of claims 1 to 8, comprising at least four plies, at least two fire-resistant layers, and a cured layer comprising one or more epoxy resins, polyacrylates, or polyurethanes.

10. The fire-resistant glazing according to any one of claims 1 to 9, comprising at least four plies, at least two fire-resistant layers, and an adhesive plastic film, wherein the adhesive plastic film is also an intermediate layer between two plies.

11. The fire-resistant glazing according to claim 10, wherein the plastic film comprises one or more of polyvinyl acetal, ionomer, polyethylene vinyl acetate, polyurethane, polycarbonate, or acrylic resin.

12. The fire-resistant glazing according to any one of claims 9 to 11, wherein the cured layer of epoxy resin, polyacrylate, or polyurethane, or the adhesive plastic film, is an intermediate layer or the outermost layer of the laminate.

13. The fire-resistant glazing according to any one of claims 1 to 12, further comprising peripheral sealing tape on the thickness-direction surface of the laminate.

14. The fire-resistant glazing according to any one of claims 1 to 12, further comprising a sealing configuration comprising a U-frame and, optionally, a thermoplastic sealant.

15. A fire-resistant glazing according to any one of claims 1 to 14, which provides EW30 performance or EI30 performance when tested in accordance with EN 1634-1 (2014).

16. (i) The steps of preparing a first laminate and a second laminate, each comprising at least two plies and at least one fire-resistant layer, where each fire-resistant layer is an intermediate layer between the two plies and is a dry layer, (ii) The step of curing a refractory layer precursor solution between the first laminate and the second laminate to form a cured layer, thereby preparing a third laminate, A method for manufacturing fire-resistant glazing according to any one of claims 1 to 15.

17. (i) The step of preparing a first laminate comprising at least two plies and at least one fire-resistant layer, wherein the fire-resistant layer is an intermediate layer between the two plies and is a dry layer, (ii) The step of preparing a second laminate by curing a refractory layer precursor solution between the first laminate and an additional ply to form a cured layer, A method for manufacturing fire-resistant glazing according to any one of claims 1 to 15.

18. (i) A step of preparing a first laminate comprising at least two plies and at least one fire-resistant layer, wherein each fire-resistant layer is an intermediate layer between the two plies and is a hardened layer, (ii) A step of preparing a second laminate by drying the refractory layer precursor solution on at least one ply to form a dry layer, (iii) The step of preparing a third laminate by pressing the first laminate onto the dry layer of the second laminate, A method for manufacturing fire-resistant glazing according to any one of claims 1 to 15.

19. (i) The step of preparing a first laminate comprising at least two plies and at least one fire-resistant layer, each fire-resistant layer being an intermediate layer between the two plies and being a hardened layer, (ii) The step of preparing a second laminate comprising at least two plies and at least one fire-resistant layer, each fire-resistant layer being an intermediate layer between the two plies and being a dry layer, (iii) The step of preparing a third laminate by stacking the first laminate on the second laminate, A method for manufacturing fire-resistant glazing according to any one of claims 1 to 15.

20. The method according to any one of claims 16 to 19, further comprising the step of cutting one or more of the first laminate, the second laminate, or the third laminate.

21. An insulated glazing unit (IGU), such as a double or triple layer, comprising at least two fire-resistant glazings according to any one of claims 1 to 15.

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