Composite materials and fire protection elements for sealing passage openings and joints in building components

Abstract

The present invention relates to a composite material, a method for producing the same, and a fire protection element, such as a building component through which a conduit is guided, containing the composite material according to the invention for protecting passage openings in building components in the event of a fire. The invention further relates to the use of the composite material as a fire protection element for sealing passage openings and / or joints in building components.

Description

[Technical Field]

[0001] The present invention relates to a composite material, a method for producing the same, and a fire protection element containing the composite material according to the invention for protecting passage openings in building elements in the event of a fire, for example a building component through which a conduit is guided. The invention further relates to the use of the composite material as a fire protection element for sealing passage openings and / or joints in elements. [Background technology]

[0002] When installing conduits such as pipelines, electrical cables, etc., they are guided through openings in building elements, particularly walls and ceilings. To prevent the passage of fire and flue gases in the event of a fire, firestop elements are introduced between the inner wall of the opening and the lines guided therethrough, entering the joints. These firestop elements are usually equipped with or made of intumescent material, so that under the influence of heat, as occurs in the event of a fire, the material expands, thereby pressing against the conduits and closing the opening in the element.

[0003] As a rule, the fire protection element contains a carrier material to which additives are added for fire protection purposes: these additives expand or foam at high temperatures, such as in the event of a fire, and together with the carrier material and optional further additives form an insulating layer, thus closing any openings that may occur.

[0004] Known fire protection elements often use physically acting foaming agents. These agents are usually randomly distributed on one or more regions of the surface of the carrier material and / or within the carrier material. In many cases, physically acting foaming agents have structural anisotropy, meaning that they can be, for example, in the form of flakes or fibers. This structural anisotropy is not taken into account in known fire protection elements, resulting in the physically acting foaming agents being randomly oriented or aligned on one or more regions of the surface of the carrier material and / or within the carrier material. Therefore, the physically acting foaming agents do not exhibit a preferred orientation. In this case, isotropic or statistical alignment or orientation of the physically acting foaming agents on one or more regions of the surface of the carrier material and / or within the carrier material is also referred to.

[0005] Due to the random orientation of the foaming agent within the carrier material, expansion or intumescence of the foaming agent occurs substantially uniformly in all three spatial directions during a fire. However, for example, in fire-stopping elements used to seal passage openings, increased expansion is required toward the passage opening to be closed. Expansion in all three spatial directions in known fire-stopping elements results in most of the expanded material being pushed laterally away from the passage opening, resulting in only a small amount of pressure being exerted toward the passage opening. Additionally, the material pushed out from the passage opening is unprotected and therefore exposed to mechanical stresses such as firewater jets and fire-induced airflow, and the extruded expanding material offers no resistance during and after a fire. Furthermore, the compressibility of the guided conduit is reduced by the material being pushed out laterally away from the passage opening, so a fast closing speed is not guaranteed during a fire.

[0006] Existing fire-stopping elements attempt to prevent the problem of lateral extrusion of the intumescent material by appropriately shaping the housing of the fire-stopping element or by using a woven fabric that surrounds the intumescent material.

[0007] For example, Patent Document 1 describes a strip-shaped fire protection element in which the inner layer of intumescent material is provided with a reinforcement over at least part of its width, so that the bend in the area of ​​the reinforcing insert forms a folded edge surrounding the reinforcing insert on the outside.

[0008] Patent document 2 describes a fire protection sleeve which is provided with a transport device for displacing material that expands under the influence of heat in the event of a fire from a support device towards the interior of the guide.

[0009] In another approach, the geometry of the fire protection element is designed to achieve improved heat input, resulting in earlier expansion of the intumescent material. Corresponding fire protection elements are described, for example, in US Pat. No. 5,623,499, US Pat. No. 5,623,499 and US Pat. No. 5,623,499.

[0010] With known firestop elements, lateral extrusion of the intumescent material can be reduced, but not prevented, resulting in a loss of material that is unavailable for closing the passage opening. Additionally, lateral extrusion of the intumescent material compresses it laterally, thereby preventing the expansion of the mechanically acting foam toward the center of the passage to close the passage. Furthermore, in these firestop elements, compression of the mechanically acting foam occurs due to compression in the wall or fabric regions of the firestop element. These compressed regions are less likely to expand and are no longer available for closing the passage in the event of a fire. Furthermore, compression causes an increase in thermal conductivity, resulting in a more rapid temperature rise on the side facing away from the fire, which is associated with an increased risk of fire penetration.

[0011] Patent Document 6 discloses a fire-resistant molded body. The fire-resistant molded body contains expandable graphite embedded in a thermoplastic resin or elastomer. The molded body described is characterized by longitudinal alignment of individual expandable graphite particles relative to the machine direction (MD). At 100x magnification, the longitudinal alignment of individual expandable graphite flakes differs from the machine direction by a maximum of ±10°. According to the teachings of this document, the expandable graphite flakes must be aligned in the MD, and vertical upright positioning of the expandable graphite particles from the machined level is prohibited. However, within the machined level, the expandable graphite particles can freely rotate 360° along their longitudinal alignment (vertical axis), resulting in radially undirectional expansion during a fire.

[0012] The above disadvantages are particularly relevant for fire protection elements with larger cross-sectional areas. These elements require large amounts of physically acting foam to ensure the passage opening is closed in the event of a fire. Therefore, the above problems are more widespread. In addition, these elements can be heavy, which makes installation difficult. Furthermore, the use of large amounts of physically acting foam is disadvantageous from an ecological and economical point of view. [Prior art documents] [Patent documents]

[0013] [Patent Document 1] European Patent Application Publication No. 3260678 [Patent Document 2] German Patent No. 2004055928 [Patent Document 3] European Patent Application Publication No. 1273841 [Patent Document 4] German Patent Application Publication No. 102008031018 [Patent Document 5] German Utility Model Application Publication No. 202012003405 [Patent Document 6] International Publication No. 2018 / 016580 Summary of the Invention [Problem to be solved by the invention]

[0014] Therefore, there is a need for a solution for reliable sealing, particularly against smoke and fire, of the gap between the inner surface of the passage opening and the conduit led therethrough in the event of a fire, which reduces the extent to which the physically acting foaming agent is pushed out of the gap as it expands, resulting in a greater pressure on the led conduit.

[0015] Additionally, it is an object of the present invention to provide a solution for use in or as a fire protection element, which solution makes it possible to reduce the use of materials, in particular the amount of physically acting foaming agent, without losing the performance of the fire protection element, in particular without impairing its closing ability in the event of a fire.In particular, it is an object of the present invention to provide a solution making it possible to reduce the amount of physically acting foaming agent in the fire protection element, so that at the same time improved performance of the fire protection element, in particular improved closing ability, can be achieved in the event of a fire. [Means for solving the problem]

[0016] This object is achieved by a composite material according to claim 1, by a method according to claim 9 and by a fire protection element according to claim 10.

[0017] According to a first aspect of the present invention, i) providing a carrier material; ii) providing a plurality of particles of at least one layer of a physically acting blowing agent; iii) mixing a carrier material with a layered physically acting blowing agent to produce a precursor; Including, the precursor is subjected to a mechanical shaping process during or after step iii) so that adjacent particles of the layered physically acting blowing agent are arranged substantially parallel to one another throughout the composite material; A composite material produced by the method is provided.

[0018] One concept of the above composite material is to use the structural anisotropy of the physically intumescent material (layered physically acting foaming agent) by combining it with a carrier material to influence and thus control the direction of expansion during a fire in a targeted manner through particle alignment or orientation. The alignment or orientation of the particles of the layered physically acting foaming agent in the carrier material is achieved during or after step iii) when the precursor is subjected to a mechanical molding process. In the case of the layered physically acting foaming agent used in the context of the present invention, expansion during a fire occurs substantially in one direction, specifically perpendicular to the individual layers in which the physically acting foaming agent is formed. If adjacent particles of the layered physically acting foaming agent are arranged substantially parallel to each other throughout the composite material, expansion during heat input occurs substantially perpendicular to the parallel particles, making it possible to control the expansion in the desired direction.

[0019] For a better understanding of the present invention, the following explanations of terms used herein are deemed useful. In the context of the present invention: - The term "composite material" describes a material obtained during manufacturing by rigidly combining different materials and whose chemical and physical properties exceed those of the individual components. The term "carrier material" describes a composition comprising one or more polymers. Carrier materials are characterized in that the one or more polymers form a continuous phase. - The term "solidly bonded" describes a bond between two materials that arises from intermolecular forces and holds the layers together so that they form a solid whole. Separation of a solid bond is often possible only by breaking the elements interconnected by the solid bond. The term "form-fitting" describes a connection between two materials that is created by the interlocking of at least two connecting parts. In the context of the present invention, a form-fitting connection may be created in particular by the plastic deformability of the polymer carrier material used to create the interlock. "Physical intumescence" means that a voluminous insulating layer is formed by the expansion of a compound that releases a gas, without any chemical reaction between the two compounds, thereby increasing the volume of the compound by a multiple of its original volume. In the context of the present invention, the term "physically acting foaming agent" means a material or component that is capable of exhibiting physical intumescence above a certain temperature, the so-called activation temperature. The term "thermal expansion" or simply "expansion" refers to the increase in volume of a material or component caused by physical and / or chemical intumescence. - A "polymer" is a molecule having six or more repeating units, and can have a linear, branched, star, twisted, hyperbranched, or crosslinked structure; a polymer can have a single type of repeating unit (a "homopolymer") or multiple types of repeating units (a "copolymer"). The term "solids content" means the non-volatile constituent content of the composition. The solids content is determined in accordance with DIN EN ISO 3251 (2008). - "Contain" and "comprise" mean that additional components may be present in addition to those stated. These terms are intended to be inclusive and therefore encompass the term "consisting of." "Consisting of" is intended to be exclusive and means that no additional components may be present. In preferred embodiments, the terms "contain" and "comprise" refer to the term "consisting of." - a range limited by a number, for example, "5 to 60% by weight," means that the two extreme values ​​and any value within the range are disclosed separately.

[0020] Step i) for producing the composite material according to the invention comprises providing a carrier material. The carrier material preferably comprises a water- or solvent-based polymer dispersion, in particular an aqueous polymer dispersion. Examples of aqueous polymer dispersions that have proven particularly useful are aqueous acrylate dispersions, urea resins, formaldehyde resins or melamine resins, aqueous dispersions or emulsions of polyvinyl acetate, polyvinyl alcohol, acrylonitrile, styrene acrylate and their copolymers.

[0021] The carrier material of the composite material according to the invention preferably comprises an aqueous acrylate (copolymer) dispersion, more preferably an aqueous dispersion of polyalkyl(meth)acrylate and / or alkyl(meth)acrylate copolymer. These are preferably aqueous dispersions obtained by polymerization, in particular by emulsion polymerization of alkyl(meth)acrylates and / or by copolymerization of alkyl(meth)acrylates with themselves and / or with copolymerizable comonomers, such as (meth)acrylic acid, (meth)acrylamide, styrene, itaconic acid, acrylonitrile, and / or citraconic acid, where the alkyl group of the alkyl(meth)acrylate preferably has 1 to 6 carbon atoms, more preferably 1 to 4 carbon atoms. Aqueous dispersions of polybutyl acrylate, polyethylhexyl acrylate, or alkyl(meth)acrylate-styrene copolymers are particularly preferred according to the invention. The acrylate (copolymer) dispersion may contain both homopolymers and copolymers, or a mixture of homopolymers and / or copolymers, and preferably has a pH in the range of 7 to 9, preferably 8, and is adjusted with dilute sodium hydroxide solution or dilute ammonia solution, if necessary, before mixing with other components. This aqueous acrylate (copolymer) dispersion preferably has a solids content of 40 to 90% by weight, more preferably 50 to 80% by weight. Acrylate (copolymer) dispersions preferably used according to the present invention are known to those skilled in the art and are commercially available. Curing occurs physically upon drying.

[0022] Furthermore, the carrier material preferably has a softening or decomposition point in the temperature range of 80°C to 500°C, preferably 90°C to 400°C, and more preferably 110°C to 300°C. By appropriately selecting the softening or decomposition temperature of the carrier material, the expansion properties of the composite material according to the present invention can be influenced. If premature softening or decomposition of the carrier material occurs during a fire, this may result in reorientation of the particles of the layered physically acting foaming agent due to deformation and / or melting of the carrier material. If the softening or decomposition temperature of the carrier material is too high, the expansion of the layered physically acting foaming agent will be hindered.

[0023] The carrier material may further comprise at least one organic and / or inorganic fiber, particularly selected from the group consisting of glass fibers, ceramic fibers, carbon fibers, polyamide fibers, metal fibers, boron fibers, natural fibers, rock fibers, and mixtures thereof. The presence of the organic and / or inorganic fiber in the carrier material facilitates the incorporation and orientation of the layered, physically acting foaming agent into the carrier material. Particularly preferred fibers are glass and / or metal fibers, especially E-glass, silicate fibers, or mineral wool fibers.

[0024] The organic or inorganic fibers preferably have a length of 1 mm to 25 mm, more preferably 2 mm to 20 mm, particularly preferably 3 mm to 15 mm. As an example, mention may be made here of STW glass fibers.

[0025] The organic or inorganic fibers are preferably contained in the carrier material in an amount of 0.1 to 25.0% by weight, preferably 0.5 to 15.0% by weight, particularly preferably 1.0 to 6.0% by weight, based on the total weight of the solid content of the composite material.

[0026] It is particularly preferred that the longitudinal extent of the organic and / or inorganic fibers is substantially parallel to the particles of the layered physically acting foaming agent, in which case the organic and / or inorganic fibers support the effect of directed expansion in one spatial direction in the event of a fire.

[0027] The ash crust formed in the event of a fire may be so unstable that, depending on its density and structure, it may be blown away by air currents, which will have a negative effect on the sealing effect of the fire protection element; the carrier material may contain at least one ash crust stabilizer.

[0028] "Ash husk stabilizers" are so-called framework-forming compounds that stabilize the carbon framework (ash husk) formed by the physically acting foaming agent and the carrier material. In this context, their basic mode of action is that the essentially very soft carbon layer formed is mechanically strengthened by inorganic compounds. The addition of such ash husk stabilizers contributes to significant stabilization of the foam husk in the event of a fire, since these additives increase the mechanical strength of the foam layer and / or prevent its deterioration, thereby maintaining or even enhancing its insulating effect.

[0029] Compounds commonly used in fire protection formulations and known to those skilled in the art, such as particulate metals such as aluminum, magnesium, iron, and zinc, may be considered ash crust stabilizers or framework formers. The particulate metals can be present in the form of powders, flakes, scales, fibers, threads, and / or whiskers. Particulate metals in the form of powders, flakes, or scales have particle sizes of ≦50 μm, preferably 0.5-10 μm. When particulate metals are used in the form of fibers, threads, and / or whiskers, a thickness of 0.5-10 μm and a length of 10-50 μm are preferred. Alternatively or additionally, oxides or compounds of metals from the group including aluminum, magnesium, iron, or zinc may be used as ash crust stabilizers, particularly iron oxides, preferably iron trioxide, titanium dioxide, and / or borates, such as zinc borate. Examples of such additives can also be found in US Pat. No. 4,442,157, US Pat. No. 3,562,197, GB Pat. No. 755,551, and EP Pat. No. 138,546.

[0030] Preferably, the ash husk stabilizer is a phosphorus-containing compound selected from salts and derivatives of phosphorus oxoacids. Phosphorus oxoacids are used because of their very wide range.

[0031] Examples of phosphate compounds include monoammonium phosphate, diammonium phosphate, ammonium phosphate, ammonium polyphosphate, melamine phosphate, melamine resin phosphate, potassium phosphate, and polyol phosphates, such as pentaerythritol phosphate, glycerol phosphate, sorbitol phosphate, mannitol phosphate, dulcitol phosphate, neopentyl glycol phosphate, ethylene glycol phosphate, and dipentaerythritol phosphate. Preferably, polyphosphates or ammonium polyphosphates are used as the phosphate compounds. In this regard, melamine resin phosphate is understood to be a compound such as the reaction product of Lamelite C (melamine-formaldehyde resin) with phosphoric acid.

[0032] The ash husk stabilizer is preferably contained in the carrier material in an amount of about 5 to 35% by weight, preferably 7 to 30% by weight, particularly preferably 10 to 28% by weight, based on the total weight of the solids content of the composite material.

[0033] In addition, other fire-protection additives may be included in the composition, especially those that cause chemical intumescence and those that act ablatively. "Chemical intumescence" refers to the formation of a large insulating ash layer by compounds that are compatible with each other and react with each other under the influence of heat. These are generally carbon sources, acid formers, and gas formers.

[0034] A "carbon source" is an organic compound that leaves a carbon skeleton and produces carbon dioxide and water upon incomplete combustion (carbonization). These compounds are also known as "carbon skeleton formers." An "acid former" is a compound that forms a non-volatile acid under the influence of heat, i.e., above about 150°C, for example, due to decomposition, thereby acting as a catalyst for carbonization. In addition, it can contribute to reducing the viscosity of the melt of the support material; the term "dehydrogenation catalyst" is used synonymously in this context. A "gas former" is a compound that decomposes at high temperatures, evolving an inert, i.e., non-combustible, gas, causing the carbon skeleton formed by carbonization and optionally the softened binder to expand into a foam (intumescence).

[0035] Optionally, the carrier material may contain other conventional additives, such as plasticizers, fillers, pigments, additives for adjusting the rheological properties, thickeners, dispersants, emulsifiers, biocides, bactericides, preservatives and antiaging agents, antifreeze agents, wetting agents, antifoaming agents, and / or skin formation retarders. These other additives are commercially available products known to those skilled in the art.

[0036] The fillers that can be used are those that are commonly used and known to those skilled in the art. The following may be mentioned as examples of fillers: chalk, barium sulfate, quartz, talc, kaolin, calcium sulfate and / or calcium silicate. The fillers can be used alone or in a mixture of two or more.

[0037] As pigments, the carrier material may preferably contain iron oxide, titanium dioxide, zinc sulfide, zinc oxide, and / or organic or inorganic color pigments.

[0038] The carrier material may contain, for example, highly dispersed silica, bentonite or modified bentonite, polyacrylates and / or cellulose derivatives, such as cellulose ethers, as additives for adjusting the rheological properties.

[0039] The additive may be contained in the carrier material in an amount of about 0.25 to 2.5% by weight, preferably 0.5 to 1.7% by weight, particularly preferably 0.8 to 1.6% by weight, based on the total solids content of the composite material.

[0040] Step ii) for producing a composite material according to the present invention comprises providing a plurality of particles of at least one layered physically acting blowing agent. In the context of the present invention, the term "layered" is understood to mean a material that is structurally anisotropic in the form of layers. The layered structure results from the fact that interactions within the layers are much more pronounced than between the layers. In the context of the present invention, this means, in particular, that covalent bonds exist within the layers, while only weak interactions in the form of electrostatic and / or van der Waals forces act between the layers. The layered physically acting blowing agent comprises a plurality of particles. It is essential for the present invention that adjacent particles of the layered physically acting blowing agent are arranged substantially parallel to each other throughout the composite material by mechanical molding.

[0041] Preferably, the layered physically acting blowing agent is in the form of flakes, with adjacent flakes oriented substantially parallel to one another throughout the composite material.

[0042] The average particle size of the layered physically acting blowing agent can be within a wide range depending on the application. Preferably, the layered physically acting blowing agent has an average particle size of 50 μm to 4.0 mm, preferably 80 μm to 3.5 mm, particularly preferably 100 μm to 3.0 mm. The average particle size can be determined by methods known to those skilled in the art, for example, by sieve analysis according to DIN 66165 (2016).

[0043] The layered physically acting blowing agent is preferably selected from the group consisting of graphite intercalation compounds (also known as expandable graphite), phyllosilicate intercalation compounds, and combinations thereof, with graphite intercalation compounds or expandable vermiculite being preferred.

[0044] SO in graphite x, NO x Known intercalation compounds of acetic acid, halogens, nitric acid, and / or strong acids can be considered as examples of graphite intercalation compounds. These are also called graphite salts. For example, graphite intercalation compounds that expand at a temperature of 120 to 350°C (activation temperature) while releasing SO2, SO3, NO, and / or NO2 are preferred. Expandable graphite suitable for the present invention is commercially available.

[0045] Preferably, the graphite intercalation compound has an average particle size of 50 μm to 1.0 mm, more preferably 70 μm to 0.7 mm, particularly preferably 90 μm to 0.5 mm.

[0046] Suitable phyllosilicate intercalation compounds (expandable phyllosilicates) are, for example, compounds that can be obtained by incorporating intercalation compounds into natural expandable phyllosilicates, in particular natural vermiculite. Representative examples of intercalation compounds include lithium and potassium alcoholates, as well as salts of lithium, sodium, and potassium with organic acids and / or their aqueous solutions, which are incorporated into natural phyllosilicates by cation exchange. In this regard, reference is made to DE-A-1 029 083 and the documents cited therein, such as EP-A-0 429 246, the contents of which are incorporated into the present application.

[0047] The phyllosilicate intercalation compound preferably has an average particle size of 100 μm to 4.0 mm, preferably 120 μm to 3.5 mm, particularly preferably 150 μm to 3.0 mm.

[0048] Step iii) for producing a composite material according to the present invention comprises mixing a carrier material with a layered physically acting blowing agent to produce a precursor. Mixing the carrier material with the layered physically acting blowing agent to produce a precursor is preferably carried out in a multi-building component mixing system. A precursor is obtained in which the layered physically acting blowing agent is uniformly and isotropically distributed within the carrier material.

[0049] Depending on the application, the layered physically acting blowing agent can be present in the precursor and correspondingly in the composite in a very wide range of weight percents, however, it is preferred that the layered physically acting blowing agent is contained in the composite in an amount of 10 to 90 wt. %, preferably 15 to 70 wt. %, more preferably 20 to 55 wt. %, based on the total weight of the solids of the composite.

[0050] To produce the composite material according to the invention, it is essential that the precursor is subjected to a mechanical shaping process during or after step iii) so that adjacent particles of the layered physically acting blowing agent are arranged substantially parallel to one another throughout the composite material.

[0051] It is essential to the present invention that adjacent particles of the layered physically acting foaming agent be arranged substantially parallel to one another throughout the composite material. In the event of a fire, the layered physically acting foaming agent expands substantially perpendicular to the layers of which it is composed. The substantially parallel alignment of adjacent particles throughout the composite material ensures that expansion occurs substantially in one spatial direction. Thus, the substantially parallel alignment of particles allows spatial control of expansion behavior during a fire. When the composite material according to the present invention is used as or in a fire-stopping element, it is possible to reduce or prevent lateral extrusion from the passage opening, since expansion is steered in a reinforcing manner toward the passage opening being closed. The layered physically acting foaming agent used is more available for closing the passage opening, resulting in an overall improvement in closing capacity, which is associated with a significant reduction in material usage for the layered physically acting foaming agent.

[0052] In the context of the present invention, the term "throughout the composite" means that, when considering the orientation of adjacent particles of the layered physically acting foaming agent, a global consideration of the composite is required, and a substantially parallel orientation of adjacent particles must exist substantially throughout the volume of the composite to achieve the requisite effect of the present invention. A local, random parallel arrangement of adjacent particles in a portion of the composite does not, in the context of the present invention, achieve the requisite effect of the present invention regarding directed expansion. However, due to the fact that the orientation is considered at the level of individual particles and their neighbors, it is not absolutely necessary that all particles of the layered physically acting foaming agent have a substantially parallel alignment. For example, when bending of the composite is present during application, adjacent particles of the layered physically acting foaming agent will be arranged substantially parallel, but due to the bending of the composite, not all particles will be arranged substantially parallel to each other.

[0053] In the context of the present invention, the term "substantially parallel" is understood to mean that adjacent particles do not need to meet the strict mathematical requirement of parallel planes, but rather a slight inclination of the plane is also acceptable. Even if the plane is slightly inclined, the above-mentioned effect of expansion occurring substantially in one spatial direction is still ensured. Furthermore, in the context of the present invention, the term "substantially parallel" also includes a situation where a small number of adjacent particles do not need to be arranged in parallel, which may be, for example, for manufacturing-related reasons. Preferably, at least 75%, more preferably at least 80%, more preferably at least 85%, more preferably at least 90%, and more preferably at least 95% of adjacent particles of the layered physically acting foaming agent exhibit a parallel arrangement.

[0054] The substantially parallel arrangement of adjacent particles of layered physically acting blowing agent throughout the composite material can be determined by visual inspection, optionally with the aid of a microscope, by one skilled in the art of composite materials.

[0055] Quantifying any particle tilt that may be present can be theoretically described by applying a right angle (90°) to any selected particle of the layered physically acting blowing agent. If this right angle is displaced with respect to adjacent particles, there is preferably a maximum angular deviation of 90° to 25°, more preferably 15°, more preferably 10°, more preferably 5°, and even more preferably 2°.

[0056] In the context of the present invention, the term "adjacent particles" is understood to mean particles that are close to a particular particle in all three spatial directions, i.e., that are arranged within a first sphere around a particle. Preferably, the term "adjacent particles" refers not only to directly adjacent particles, but also to particles that are directly adjacent to a particle that is directly adjacent to a particle, i.e., that are arranged around the particle beyond the first sphere and within a second sphere.

[0057] During the manufacture of the composite material according to the invention, adjacent particles of the layered physically acting blowing agent are arranged substantially parallel to one another throughout the composite material by mechanical molding. Within the composite material, all particles of the layered physically acting blowing agent can be arranged substantially parallel to one another. This constitutes a preferred embodiment of the invention.

[0058] However, substantially parallel alignment of all particles of the layered physically acting foaming agent is not absolutely necessary to achieve the essential inventive effect of targeted expansion in substantially one spatial direction. This is the case, for example, when the composite material according to the invention is in the form of a long bandage that is wound around a conduit guide through a passage opening. In this case, adjacent particles of the layered physically acting foaming agent are arranged substantially parallel, but due to the winding and associated bending of the bandage, not all particles are arranged substantially parallel to each other. In this case, if adjacent particles are arranged substantially parallel to each other in the longitudinal direction of the bandage throughout the composite material, expansion in the event of a fire will occur substantially in the direction of the center of the passage opening.

[0059] Preferably, the mechanical shaping method is selected from the group consisting of extrusion with a molded mouthpiece of specific geometry, injection molding, squeegeeing, calendering, pultrusion, and combinations thereof. Preferably, the mechanical shaping method is selected from extrusion with a molded mouthpiece of specific geometry and / or calendering.

[0060] Within the context of the present invention, the term "extrusion" is understood to mean the extrusion of a mass through a molding orifice under pressure. The molding orifice is also referred to as a mouthpiece. Preferably, the extrusion is carried out using a piston or screw extruder. The use of a mouthpiece with a special geometry, with a height-to-length ratio as small as possible, allows for the alignment of adjacent particles of the layered, physically acting blowing agent throughout the entire composite. Advantageously, the dimensions of the mouthpiece (length:height) are in the range of 310 mm:10 mm to 7 mm:0.5 mm. It is further preferred that the maximum height of the mouthpiece is ≦10 mm, more preferably ≦5 mm, in particular ≦2 mm, more preferably ≦1.5 mm, and particularly preferably ≦1.0 mm.

[0061] In the context of the present invention, the term "squeegeeing" is understood to mean the method of applying a precursor to a surface using a squeegee.

[0062] In the context of the present invention, the term "calendering" is understood to mean a method in which a calender containing one or more rollers is used. The precursor prepared in step iii) is passed through the gap between the rollers once or several times. Advantageously, this step is carried out several times, for example, four or five times. In this case, it is also advantageous to gradually decrease the gap between the rollers with each step. Preferably, the rollers have a gap of ≦10 mm, more preferably in the range of 0.5 mm to 8 mm, more preferably 1.0 mm to 5.0 mm, and most preferably 1.0 to 3.0 mm.

[0063] In the context of the present invention, the term "pultrusion" is understood to mean a method in which a precursor is applied to a material to be stretched, such as a woven glass fiber fabric, and a tensile force is then applied to this material.

[0064] In the context of the present invention, the term "injection molding" is understood to mean a method in which a precursor is liquefied in an injection molding machine and injected under pressure into a mold.

[0065] According to a preferred embodiment, the composite material according to the invention is in the form of a mouldable mass or as a moulded part, in particular in the form of a strip, ring or plate.

[0066] The composite material preferably has a maximum average layer thickness of ≦10 mm, more preferably ≦8 mm, particularly preferably ≦5 mm. In a preferred embodiment, the composite material has an average layer thickness of 0.5 mm to 4.6 mm.

[0067] The embodiments will now be described in more detail with reference to the accompanying drawings. [Brief explanation of the drawings]

[0068] [Figure 1] 1 is a cross-sectional view of an embodiment of a composite material according to the present invention. [Figure 2] 1 is a schematic diagram of a preferred composite material according to the present invention. [Figure 3] 1 is a photograph of a fire protection element known from the prior art, which comprises expandable graphite embedded in a polymeric carrier material. [Figure 4] 1 is a photograph of the test setup. [Figure 5] 1 is a graph showing the evaluation of expansion trials of a composite material according to the invention in comparison with fire protection elements known from the prior art; DETAILED DESCRIPTION OF THE INVENTION

[0069] Figure 1 shows a cross-sectional view of an embodiment of a composite material (1) according to the present invention. The composite material (1) comprises a carrier material (2) and at least one layer of physically acting blowing agent (3). Adjacent particles of the layer of physically acting blowing agent (3) are arranged substantially parallel to one another. The layer of physically acting blowing agent (3) is embedded in the carrier material (2) and is substantially uniformly distributed within the carrier material (2).

[0070] Figure 2 is a three-dimensional view of a preferred composite material (1) according to the present invention. The particles of the layered physical blowing agent (3) are shown in the form of flattened cuboids. Adjacent particles of the layered physical blowing agent (3) are arranged parallel to one another throughout the composite material (1). Figure 2 shows a preferred embodiment in which all adjacent particles of the layered physical blowing agent (3) are arranged parallel to one another throughout the composite material (1).

[0071] FIG. 3 is a photograph of a microscopic analysis (25x magnification) of a composite material (4) known from the prior art, used as an intumescent inlay in a fire sleeve (Hilti, CP644 fire sleeve, composite layer thickness 4.5 mm). The inlay was produced by extrusion using a standard die and contains a plurality of expandable graphite particles (6) embedded in a polymer carrier material (5). The microscopic analysis shows that the individual expandable graphite particles (6) are aligned in the machine direction. Observation of the entire inlay reveals that the individual expandable graphite particles (6) along the work surface exhibit an isotropic, random alignment, in which adjacent expandable graphite particles may be arranged parallel to one another at individual local points. The photograph also shows that there is no substantially parallel orientation of adjacent expandable graphite particles (6) throughout the inlay.

[0072] FIG. 4 is a photograph of a test setup that allows for the establishment of a substantially parallel arrangement of adjacent particles of layered physically acting blowing agent.

[0073] FIG. 5 shows a graphical evaluation of the expansion trials of a composite material according to the invention compared with fire protection elements known from the prior art.

[0074] The invention is not limited to the examples shown, and in particular individual features of one example may be included in further examples according to the invention independently of other features of the corresponding example, i.e. the described features may be combined with one another as required.

[0075] According to a second aspect of the present invention, a method for producing a medicament for the treatment of a cancer, comprising the steps of: i) providing a carrier material; ii) providing a plurality of particles of at least one layer of a physically acting blowing agent; iii) mixing a carrier material with a layered physically acting blowing agent to produce a precursor; Including, the precursor is subjected to a mechanical shaping process during or after step iii) so that adjacent particles of the layered physically acting blowing agent are arranged substantially parallel to one another throughout the composite material; A method for producing a composite material according to the invention is provided, characterized in that:

[0076] The statements made above regarding the production of the composite material according to the invention apply analogously to the method according to the invention.

[0077] The composite material according to the invention is suitable for use as or integration into a fire protection element.Therefore, according to a third aspect of the invention there is provided a fire protection element comprising a composite material according to the invention.

[0078] The fire protection element according to the invention can be constructed in all forms that geometrically allow its use as a fire protection element. In a preferred embodiment, the fire protection element is strip-shaped and in the form of an endless bandage.

[0079] The fire protection element according to the present invention may comprise one or more composite materials according to the present invention. When the fire protection element comprises multiple composite materials, it is advantageous to arrange a functional layer between the composite materials when two or more composite materials are layered. The functional layer preferably extends continuously between the two or more composite materials. Preferably, the functional layer comprises or consists of at least one semi-rigid material. In the context of the present invention, the term "semi-rigid material" is understood to mean a material that has both sufficient mechanical strength to absorb the expansion pressure emanating from the composite material without being destroyed and sufficient flexibility so that the expansion of the layered, physically acting foaming agent is not hindered. It has proven advantageous for the semi-rigid material to be selected from the group consisting of expanded metal, glass fiber, aluminum foil, and combinations thereof.

[0080] The invention further relates to the use of the composite material according to the invention as a fire protection element for sealing passage openings and / or joints in building elements.

[0081] The invention will now be described in more detail with reference to the following examples. [Example]

[0082] Formulations were prepared using the components listed in Table 1 below. The indicated components were mixed together. The prepared formulations, which include a carrier material and a layered physically acting blowing agent, can be used as starting materials for the production of composite materials according to the present invention. [Table 1]

[0083] To produce the composite material according to the present invention, a specified amount of the above-mentioned formulation was applied to a smooth-surfaced PE film, which was then wrapped around the starting material to coat both sides. The starting material coated with the PE film (10 mm thick) was then calendered (the distance between the rollers in the calender was 0.5 mm to 10.0 mm). The distance between the rollers in the calender was reduced by 1 mm each time, and the above steps were repeated until the desired layer thickness was reached. To smooth the surface, the final treatment step was carried out twice with the calender. Alternatively, this step was carried out by applying pressure through the rollers. The composite material thus produced exhibited a substantially parallel alignment of adjacent particles of the layered, physically acting blowing agent within the carrier material, as determined by visual inspection under a microscope.

[0084] Furthermore, a composite material according to the invention (Composite Material 2) was produced according to the above description, using the product CP648-E from Hilti as the starting material as the formulation. This formulation comprises a carrier material (aqueous acrylate dispersion) and a layer of physically acting blowing agent.

[0085] To measure the expansion characteristics of the manufactured composites, the expansion volume (upward expansion) was measured using a device for functional displacement testing. For comparison, the so-called expansion coefficient could be determined from these measurements, which represents the ratio of the expansion height of the composite to its total weight. The measuring device for the functional displacement test consisted of two heatable plates arranged horizontally. The top plates had a constant weight. The composite to be measured (circular, 45 mm diameter) was placed between the heatable plates and subjected to a temperature program (starting temperature 50 °C, heating rate 20 °C / min, intermediate temperature 100 °C (5 min), heating rate 20 °C, final temperature 500 °C (hold time 15 min). The top plates allowed the expansion height to be recorded.

[0086] To demonstrate the substantially parallel alignment of adjacent particles of layered physically acting blowing agent throughout the composite, the following test setup was chosen: Strips of 4.5 mm and 5.00 mm thickness were cut from the relevant composite and these strips were rolled up as shown in Figure 2. The strips were rolled up so that expansion occurred in the x-direction (=height) (Example 2) and the strips were rotated by 90° so that expansion occurred in the planar direction (Example 1). Example 1: Sample rotated by 90°, assumption: predominantly planar expansion. Example 2: Rolled sample, assumption: expansion mainly in height. Example 3: Punched reference sample, diameter 45 mm.

[0087] In addition to the swelling height, the total surface area of ​​the swollen sample was measured by the software with reference to the photograph. [Table 2]

[0088] It was found that all samples from Example 1 had only a low expansion height but showed a significant increase in total surface area. Composite 1 and 2 samples from Examples 2 and 3 expanded significantly more in height by comparison, but remained significantly less in total surface area.

[0089] Furthermore, the expansion characteristics of the composite material 2 of the present invention were investigated using the above-described device for functional displacement testing, and compared with those of the commercially available product Fi-Block® Firewrap (available in two thicknesses: 0.9 mm and 2.45 mm) from Sekisui Chemical Co., Ltd. (Japan). This product is based on a polymer carrier material in which expandable graphite is embedded. To measure the expansion characteristics of the commercially available Fi-Block® Firewrap, circular samples weighing 1.60 g (0.9 mm thick) and 6.33 g (2.45 mm thick) were punched out. These samples were placed in the device for functional displacement testing, the temperature program was initiated, and the upward expansion was measured. The results are shown in Figure 5, comparing the expansion results of the composite material of the present invention with those of the non-inventive composite. It was shown that the non-inventive sample exhibited a substantially lower expansion height than the composite material of the present invention. Furthermore, the occurrence of negative expansion heights in the non-inventive sample can be explained by the melting of the polymer carrier material, which occurs before the expansion of the expandable graphite occurs.

Claims

1. i) providing a carrier material; ii) providing a plurality of particles of at least one layer of a physically acting blowing agent; iii) mixing the carrier material with the layered physically acting blowing agent to produce a precursor; 1. A method for producing a composite material comprising: the support material comprises at least one organic and / or inorganic fiber; the precursor is subjected to a mechanical shaping process during or after step iii), so that adjacent particles of the layered physically acting blowing agent are arranged substantially parallel to one another throughout the composite material; the mechanical molding method is extrusion or calendar molding; the carrier material comprises an aqueous polymer dispersion; and The layered physically acting blowing agent is a graphite intercalation compound. A method characterized by:

2. 2. The method of claim 1, wherein the composite material has a maximum layer thickness of ≦10 mm.

3. 3. The method according to claim 1, wherein the layered physically acting blowing agent has an average particle size of 50 μm to 4 mm.

Images