Fire protection system

Abstract

The invention relates to a process for producing a fire protection system, comprising metering a comminuted silicon dioxide raw material and a granulated alkali metal hydroxide into a reactor; adding water in the reactor and mixing the ingredients, resulting in spontaneous heating, until a hot semifinished product is obtained; storing this semifinished product until a homogeneous colloidal aqueous dispersion (4) of the alkali metal hydrosilicate is obtained; applying the homogeneous colloidal aqueous dispersion (4) and a reinforcement (3) between a first substrate (1) and a second substrate (7); pressing or hot pressing the fire protection system into a three-dimensional shape and / or to form a rigid article. The invention additionally relates to a ready-to-use fire protection system comprising a dispersion (4) of an alkali metal hydrosilicate and at least a first substrate (1) and a second substrate (7), between which the dispersion (4) and at least one layer of a reinforcement (3) are provided, wherein the fire protection system is provided in a three-dimensional shape and / or in the form of a rigid article by pressing or hot pressing.

Description

[0001] FIRE PROTECTION SYSTEM

[0002] The invention relates to a fire protection system, in particular a ready-to-use fire protection system, and its manufacture and use.

[0003] The invention relates in particular to a fire protection system based on alkali metal hydrosilicates, preferably sodium hydrosilicate, which is preferably obtained by alkalizing natural silicate raw material.

[0004] This application is based on the applicant's earlier application, published under numbers EP4165145A2, AT523824B1, CN115720591A and US2023340332A1. This application aims to improve or further develop the earlier patent.

[0005] The dispersion of the alkali metal hydrosilicate can be prepared as disclosed in EP4165145A2, but this is not to be understood as a limitation. The process disclosed in EP4165145A2 comprises the following:

[0006] Dosage of a crushed silicon dioxide raw material and a granulated alkali metal hydroxide into a reactor;

[0007] Adding water to the reactor and mixing under self-heating until a hot semi-finished product is obtained;

[0008] Storage of this semi-finished product until a homogeneous colloidal aqueous dispersion of the alkali metal hydrosilicate is obtained;

[0009] Application of the homogeneous colloidal aqueous dispersion onto a substrate.

[0010] The method disclosed in EP4165145A2 preferably comprises the following:

[0011] • Comminution of porous silicon dioxide raw materials, preferably to a particle size that provides a specific surface area of ​​the material in the range of 0.05-0.5 m² 2 / grams

[0012] • Dosage of this raw material and granulated alkali metal hydroxide (preferably air-dried),

[0013] • Irrigation in the reactor and mixing under self-heating until a hot semi-finished product is obtained,

[0014] • Unloading the hot semi-finished product into a container and storing this semi-finished product in the container or storage in the reactor until a homogeneous colloidal aqueous dispersion of the alkali metal hydrosilicate is obtained.

[0015] The method disclosed in EP4165145A2 preferably further comprises:

[0016] • The manufacture of a fire protection system consisting of a colloidal aqueous dispersion of an alkali metal hydrosilicate, a reinforcement material and a separating film.

[0017] • Packaging of cut-outs of the fire protection system in vacuum packaging.

[0018] The ratio of the dry weight of the silicon dioxide raw material to the dry weight of the alkali metal hydroxide in EP4165145A2 is preferably in the range of 1:1 to 5:1. The object of the present invention is to further develop the process and the product of EP4165145A2.

[0019] For this purpose, a method according to claim 1 and a ready-to-use fire protection system according to claim 17 are proposed.

[0020] One implementation variant concerns a method for manufacturing a fire protection system, comprising:

[0021] Dosage of a crushed silicon dioxide raw material and a granulated alkali metal hydroxide into a reactor;

[0022] Adding water to the reactor and mixing under self-heating until a hot semi-finished product is obtained;

[0023] Storage of this semi-finished product until a homogeneous colloidal aqueous dispersion of the alkali metal hydrosilicate is obtained;

[0024] Application of the homogeneous colloidal aqueous dispersion onto a first substrate;

[0025] Applying reinforcement to the first substrate or dispersion, depending on the order of application of the dispersion and reinforcement;

[0026] Application of a second substrate over the dispersion and the reinforcement,

[0027] Pressing or hot pressing the fire protection system into a three-dimensional shape and / or into a rigid object.

[0028] In one variant, the fire protection system is deformed into a three-dimensional shape by hot pressing.

[0029] In one variant, the fire protection system is transformed into a rigid object by hot pressing.

[0030] In one variant, the fire protection system is transformed into a rigid object with a three-dimensional shape by hot pressing.

[0031] Prior to hot pressing, the fire protection system is preferably in the form of a two-dimensional element or a sheet structure. The substrates are preferably homogeneous sheet structures, in particular films.

[0032] It is preferred that the dispersion is cured in two steps, wherein in a first step a shaping is carried out by hot pressing the two-dimensional fire protection system into a three-dimensional shape and in a second step the three-dimensional fire protection system is applied to a surface or element to be protected.

[0033] Preferably, the conversion into a rigid object is achieved by partially drying the dispersion. Both substrates can be elastic in this process. The partial drying takes place at a specific temperature and over a period of time until the dispersion is dimensionally stable and retains its three-dimensional shape.

[0034] Hot pressing is carried out at a temperature higher than the ambient temperature. It can be performed in a heated mold and / or with a heated pressing tool. The temperature during hot pressing is preferably in the range of 50 to 250°C, particularly 100 to 250°C. Hot pressing is preferably carried out for a duration of at least 1 hour, preferably at least 5 hours. Pressing can be performed at a pressure higher than the ambient pressure. The pressure can be, for example, in the range of 1.1 to 15 bar. Suitable parameters can be determined experimentally and depend in particular on the desired residual moisture or water content of the dispersion and its layer thickness. Generally, the desired residual moisture content is reached more quickly at higher temperatures.

[0035] In one embodiment, at least one of the two substrates is plastically deformable, so that the transformation into a rigid object occurs through the deformation of at least one substrate. Partial drying can also take place in this process.

[0036] It is preferred that the pressing or hot pressing of the fire protection system takes place in a mold, wherein the fire protection system has the first substrate and the second substrate during pressing or hot pressing, between which the colloidal aqueous dispersion of the alkali metal hydrosilicate and at least one layer of the reinforcement is located.

[0037] In various designs, several layers of the fire protection system are placed in one mold, with one of the following measures: a separating film is placed between the layers, or there is no separating film between the layers, or a perforated or cut-out separating film is placed between the layers.

[0038] Preferably, the fire protection system is attached to the element to be protected by pressing or hot pressing, preferably by pressing the element into a housing that serves as a mold. The housing is either the element to be protected or the housing of the element to be protected.

[0039] It is preferred that the dispersion or reinforcement is exposed on the side facing the element to be protected, by removing a substrate.

[0040] It is preferred that at least one of the substrates is a material that can be plastically deformed by pressing.

[0041] It is preferred that at least one of the substrates is in the form of a metal sheet, deep-drawn sheet or thermoplastic plastic film, deep-drawn film or thermoforming film.

[0042] Preferably, the formation of a hard gel of an alkali metal hydrosilicate, i.e., the curing of the dispersion, takes place in two stages. In the first stage, the fire protection system is transformed into a rigid object by hot pressing, and in the second stage, the rigid object is placed on the surface to be protected or additionally bonded to it. Drying to a hard gel is only completed on the surface to be protected, since the finished rolls / sets of the fire protection system are packaged in a vacuum-sealed container that prevents dehydration of the aqueous dispersion of the alkali metal hydrosilicate.

[0043] Preferably, the mixture or the hot semi-finished product reaches a temperature in the range of 60°C-100°C through self-heating in the reactor.

[0044] The silicon dioxide raw material is preferably silica of natural origin. Silica is specifically defined as a mineral with a high silicon content. No pyrogenic SiO2, precipitated SiO2, or silica sol is used.

[0045] The alkali metal hydroxide is preferably sodium hydroxide (NaOH). Preferably, no KOH is added during the manufacturing process. Particularly preferably, only NaOH is added during the manufacturing process.

[0046] Preferably, only silicon dioxide raw material, in particular silica, and alkali metal hydroxide, in particular sodium hydroxide, and water are added during the manufacturing process.

[0047] Preferably, no defoaming agent such as polyol and / or syloxane is used. Preferably, no ammonium salt is added to reduce viscosity. In the manufacturing process according to the invention, preferably no glycerin, syloxane, polyol, and / or ammonia is added.

[0048] Preferably, the method for manufacturing a fire protection system includes:

[0049] Comminution of a silicon dioxide raw material to a particle size that results in a specific surface area of ​​the material in the range of 0.05 to 0.5 m² 2 / gram;

[0050] Dosage of the crushed silicon dioxide raw material and an air-dried, granulated alkali metal hydroxide into a reactor;

[0051] Adding water to the reactor and mixing under self-heating until a hot semi-finished product is obtained;

[0052] Filling the hot semi-finished product into a container and storing this semi-finished product in the container until a homogeneous colloidal aqueous dispersion of the alkali metal hydrosilicate is obtained; applying the homogeneous colloidal aqueous dispersion to a substrate.

[0053] The homogeneous colloidal aqueous dispersion is preferably applied to the substrate without pre-drying, and preferably no pre-drying takes place on the substrate either, in particular no pre-drying in an oven.

[0054] To prevent patent protection from being circumvented by over-fulfilling requirements or adding unnecessary steps, the following points should be noted:

[0055] Silicon dioxide raw material is preferably reduced to a particle size that gives a specific surface area of ​​the material in the range of 0.05 to 0.5 m². 2 The product is comminuted into gram-sized pieces. Further comminution is not required for the manufacturing process but is not excluded and is therefore included in the present invention. Finer comminution is generally disadvantageous, as it is usually associated with higher costs.

[0056] The use of a pre-shredded raw material, so that the shredding does not take place on site, is also possible and is included in the present invention.

[0057] The granulated alkali metal hydroxide is preferably air-dried. Special storage in a controlled atmosphere or drying or moistening of the alkali metal hydroxide before introduction into the reactor is not necessary, but conceivable and encompassed by the present invention.

[0058] The reaction occurs through self-heating. An input or output of heat energy via the reactor is not necessary, but also not excluded, and is therefore included in the present invention.

[0059] The semi-finished product is preferably transferred from the reactor into a container. However, using the reactor itself as a container, or allowing the reaction to take place in a suitable container, seems fundamentally conceivable in batch production and is included in the invention.

[0060] Preferably, the homogeneous colloidal aqueous dispersion is applied to a first substrate in the form of a separating film.

[0061] A separating film is also preferred as the second substrate.

[0062] Preferably, reinforcement is inserted into or placed on top of the applied homogeneous colloidal aqueous dispersion.

[0063] Preferably, the ratio of the mass of the layer of colloidal aqueous dispersion of alkali metal hydrosilicate and the mass of the reinforcing material is in the range of 10:1 to 2:1.

[0064] Preferably, a strip of the fire protection system is rolled into a roll.

[0065] In one version, the fire protection system is packaged airtight or vacuum-packed while the colloidal aqueous dispersion is liquid. The dispersion thus remains liquid within the packaging and only hardens after the packaging is opened.

[0066] Preferably, pressing or hot pressing takes place before the fire protection system is hermetically sealed or vacuum-packed, or after the hermetically sealed packaging has been removed. In one embodiment, the fire protection system is hermetically sealed or vacuum-packed until the colloidal aqueous dispersion has fully cured. The dispersion only cures completely after the packaging is opened.

[0067] In one embodiment, the invention comprises a ready-to-use fire protection system comprising a dispersion of an alkali metal hydrosilicate and at least a first substrate and a second substrate, between which the dispersion and at least one layer of reinforcement are located, wherein the fire protection system is formed by pressing or hot pressing with a three-dimensional shape and / or as a rigid object.

[0068] In one version, the ready-to-use fire protection system is available in three-dimensional form.

[0069] In one version, the ready-to-use fire protection system is available as a rigid object.

[0070] In one version, the ready-to-use fire protection system is a rigid object with a three-dimensional shape.

[0071] In one embodiment, the invention comprises a ready-to-use fire protection system comprising a dispersion of an alkali metal hydrosilicate, a substrate and a reinforcement, wherein the fire protection system is provided in an airtight package or a vacuum package and wherein the reinforcement comprises at least one layer of a flexible sheet structure of a non-woven fiber material.

[0072] Preferably, the colloidal aqueous dispersion of the alkali metal hydrosilicate in the vacuum-packed state exhibits high adhesion to metal, wood and concrete surfaces, preferably for a period of at least one year.

[0073] Preferably, the reinforcement is permeable to the dispersion. Preferably, the dispersion penetrates between the fibers of the non-woven fiber material.

[0074] The reinforcement is preferably a thin sheet material produced by mechanical or chemical processing of discontinuous fibers – preferably ceramic fibers, artificial mineral fibers, cellulose fibers, polymer fibers, or mixtures thereof. The sheet material can be without or with additional holes. Additional holes are understood to be perforations in the sheet material.

[0075] For example, producing holes with a diameter of about 1 mm and a total area of ​​the openings of about 5.2% of the total area of ​​the paper reinforcement after impregnation according to the present invention leads to an increase in the amount of aqueous dispersion of an alkali metal hydrosilicate in the fire protection system by about 17%.

[0076] The mass of the layer of colloidal aqueous dispersion of the alkali metal hydrosilicate is preferably greater than the mass of the reinforcement.

[0077] The ratio of the mass of the colloidal aqueous dispersion layer to the mass of the reinforcement is preferably in the range of 30:1 to 6:1, in particular 30:1 to 11:1.

[0078] The reinforcement can be in the form of a reinforcing paper, which includes ceramic fibers, artificial mineral fibers, cellulose fibers, polymer fibers or mixtures thereof.

[0079] The reinforcing paper is preferably impregnated with the dispersion. The dispersion preferably penetrates between the fibers of the reinforcing paper. Preferably, the fire protection system comprises a first substrate and a second substrate, with the dispersion and the reinforcement located between the first and second substrates.

[0080] Preferably the substrate, in particular the first substrate and the second substrate, is a separating film which is dense to the dispersion.

[0081] In one version, the first substrate and the second substrate are different, with one of the substrates being a peelable separating film and the other substrate remaining on the surface.

[0082] The substrate remaining on the surface can be a decorative layer or fulfill a technical function, such as shielding against weathering or light exposure.

[0083] The first substrate and the second substrate can be in the form of a plastic film or metal film, or as a laminate made of several films.

[0084] In one embodiment, the invention comprises the use of the ready-to-use fire protection system, wherein the fire protection system is applied to a surface to be protected after opening or removing the packaging or vacuum packaging, and the colloidal aqueous dispersion of the alkali metal hydrosilicate subsequently hardens.

[0085] Preferably, one of the two substrates, between which the colloidal aqueous dispersion of the alkali metal hydrosilicate is present, is removed when applying it to the surface to be protected.

[0086] Preferably, the colloidal aqueous dispersion of the alkali metal hydrosilicate is present on a reinforcement which remains on the surface to be protected.

[0087] In one version, the colloidal aqueous dispersion of the alkali metal hydrosilicate is contained on or in a reinforcing paper that remains on the surface to be protected.

[0088] Preferably, at least one layer of a reinforcement made of a non-woven fiber material coated with the colloidal aqueous dispersion is applied to the surface to be protected.

[0089] In one variant, at least two layers of a reinforcement coated with the colloidal aqueous dispersion are applied one on top of the other to the surface to be protected.

[0090] In one design variant, the substrate located on the outer surface of the reinforcement can be removed when the fire protection system is applied to the surface to be protected.

[0091] Examples of how to implement the invention

[0092] The invention is explained below by a detailed description of a manufacturing process for the fire protection system and its use for fire protection of building structures.

[0093] The weight ratio of water to dry raw materials is preferably between 1:0.5 and 1:2.5. Preferably, the moisture content of the silica is measured in the raw material silo and the amount of water supplied to the reactor is adjusted accordingly.

[0094] Preferably, the process of mixing the raw components is not carried out until a hot-viscous semi-finished product is obtained, but only until alkali metal hydrosilicate with a silicate modulus m = 3.0 to 4.5 - in particular 3.5 to 4.5 - is formed in the mixture.

[0095] Mixing preferably takes place over a period of 0.1 to 0.5 hours.

[0096] The formation of the hydrosilicate in the mixture is controlled by sampling directly from the reactor.

[0097] The sample quality can be determined visually by a number of criteria - the specific gloss (which is compared to the etalon using special equipment) and the formation rate of the surface film.

[0098] After the mixing process is completed, the hot colloidal aqueous dispersion of an alkali metal hydrosilicate is placed in a container in which a physicochemical reaction of water binding in the dispersion takes place, preferably for at least 24 hours, with increasing viscosity of the mixture.

[0099] The dispersion is preferably stored for a period of 18 to 36 hours.

[0100] The readiness / maturity of the colloidal dispersion can be determined by rheological properties similar to buttercream.

[0101] In a preferred method of manufacturing a fire protection system, the finished colloidal dispersion is applied to a substrate, in particular a separating film substrate, with a layer thickness of preferably 1-3 mm, and then the reinforcement is applied to the surface of the dispersion.

[0102] Then a second substrate, in particular a separating film substrate, is applied to the dispersion.

[0103] The finished system is preferably rolled up.

[0104] The finished system can, for example, be divided into pieces 1 to 3 meters long, which are preferably wound onto cardboard or plastic tubes and preferably packed in vacuum packaging.

[0105] In such packaging, the fire protection system can preferably be stored for 3 to 4 years without loss of properties.

[0106] Industrial applicability

[0107] The present method makes it possible to obtain a universal product with a very wide range of applications and high fire protection effectiveness.

[0108] Exemplary application areas of the fire protection system according to the invention include the fire protection of steel, wood and concrete structures, air ducts, cable trays, housings, shields, etc. The system can also be used in the manufacture of fire doors or gates as well as in the sealing of pipe and cable penetrations in fire-resistant walls and ceilings.

[0109] The use of the fire protection system according to the present invention does not require any special equipment and / or special qualifications of personnel.

[0110] After unpacking and removing the packaging, especially vacuum packaging, the strips of the fire protection system are simply stuck onto the surface to be protected after peeling off the first or second substrate.

[0111] During bonding, the other of the two substrates can be removed, with the bonding occurring through adhesion of the colloidal dispersion of alkali metal hydrosilicate to the surface to be protected. In another embodiment, either the first or the second substrate can remain on the surface.

[0112] The fire protection system in question can be wrapped around the perimeter of linear structures with access from all sides (columns, air ducts, pipes, elements of roof trusses) like a bandage.

[0113] The fire protection system in question can be glued to the surface of flat structures and / or structures with restricted access in the form of strips.

[0114] Due to the presence of reinforcement, several layers of the fire protection system can be applied in one operation, making it possible to achieve the required fire resistance of the structure with minimal effort.

[0115] Standard industrial equipment is suitable for producing a comprehensive fire protection system consisting of a colloidal dispersion of an alkali metal hydrosilicate. The substrates and reinforcement are preferably fed from rollers. A single layer of colloidal dispersion is preferably applied between the two substrates, and the finished system is then wound into a roll.

[0116] Standard industrial packaging machines are used for the vacuum packaging of cut pieces and / or rolls of the fire protection system.

[0117] The finished fire-resistant system may be stored in warehouses without forced air and exhaust air, heating and fire alarm systems, and automatic fire extinguishing.

[0118] Multiple freezing and thawing cycles are possible during storage.

[0119] Furthermore, in one embodiment, the present invention comprises the use of the ready-to-use fire protection system, wherein the fire protection system is applied to a surface or element to be protected in two steps. In the first step, the fire protection system is transformed into a rigid object by pressing, in particular hot pressing, and in the second step, the rigid object is applied to the surface or element to be protected or additionally bonded to it. The transformation into a rigid object is achieved by partially drying the dispersion. The pressing of the fire protection system takes place in a mold, wherein the fire protection system preferably comprises a first substrate and a second substrate, between which the colloidal aqueous dispersion of the alkali metal hydrosilicate and at least one layer of reinforcement are located.Optionally, multiple layers of the fire protection system can be placed in a single mold. The layers can be separated by release liners, or there can be no release liner between the layers, or a perforated or cut-out release liner can be used between the layers. These different variations result in varying degrees of adhesion between the layers after pressing.

[0120] Depending on whether the pressing takes place at the manufacturing site or at the point of use, it can be performed before or after airtight packaging. In the first case, the pressed and airtight-sealed fire protection system can be stored and / or transported until needed. In the second case, the airtight-sealed fire protection system can be stored and / or transported in its unpressed state and pressed into the required shape at the point of use. Another design option involves hot-pressing the fire protection system onto the element to be protected, for example, by pressing it into a housing that serves as a mold. In this case, the dispersion or reinforcement on the side facing the element to be protected may be exposed, for example, by removing a substrate.

[0121] In one embodiment, at least one of the substrates can be a material that can be plastically deformed by pressing, for example as a metal sheet or as a thermoplastic plastic film, in particular as a deep-drawing sheet or deep-drawing film or thermoforming film.

[0122] The following figures schematically illustrate the manufacture and use of a fire protection system of the invention in question.

[0123] Fig. 1 illustrates the manufacture of a fire protection system according to the present invention.

[0124] Fig. 2 illustrates the use of a fire protection system according to the present invention.

[0125] Figure 1 illustrates the production of a fire protection system comprising a first substrate 1, preferably in the form of a separating film, onto which a colloidal aqueous dispersion 4 of an alkali metal hydrosilicate is applied and which has a reinforcement 3. The reinforcement 3 can be applied before or after the dispersion 4, or simultaneously. A second substrate 7 is applied after the reinforcement 3 and the dispersion 4.

[0126] Preferably, the substrate 1 is unwound from a roll and moved by an application device 2. The application device 2 preferably comprises at least one spray nozzle with which the dispersion 4 is applied. Before, during, or after the application of the dispersion 4, a reinforcement 3 is preferably also unwound from a material roll and applied or laid onto the first substrate 1 or the dispersion 4.

[0127] The second substrate 7 is preferably also unwound from a roll and applied opposite the first substrate 1.

[0128] In one embodiment, the first substrate 1 and / or the second substrate 7 has a greater width than the dispersion coating and the reinforcement 3. In another embodiment, the two substrates 1, 7 are adjacent to each other in both lateral edge areas of the fire protection system.

[0129] In one embodiment, the application of the dispersion 4 and the reinforcement 3 is discontinuous, so that between areas with dispersion 4 and reinforcement 3 there is a section in which the two substrates 1, 7 are in contact with each other.

[0130] In one embodiment, the two substrates 1, 7 are welded or glued together in the areas where they are in contact. This allows for airtight packaging through the two substrates 1, 7.

[0131] All methods are possible for the production of the fire protection system which include impregnating the reinforcement with the colloidal dispersion 4 and coating both sides with a first substrate 1 and a second substrate 7 and include airtight packaging or vacuum packaging of the colloidal dispersion 4.

[0132] The preferred fire protection system consists of the following layers: first substrate 1 - dispersion 4 and reinforcement 3.

[0133] - The second substrate 7 is rolled into a roll 5. The roll 5 or another packaging unit of the fire protection system is then hermetically sealed, preferably vacuum-packed.

[0134] This ensures that the dispersion 4 retains its liquid and only dries and hardens after the packaging is opened.

[0135] The first substrate 1 is preferably flexible. The first substrate 1 is preferably a plastic film. The first substrate 1 is preferably impermeable to the dispersion 4 and its liquid components.

[0136] The second substrate 7 is preferably flexible. The second substrate 7 is preferably a plastic film. The second substrate 7 is preferably impermeable to the dispersion 4 and its liquid components.

[0137] The reinforcement 3 is preferably a layer of a flexible sheet structure made of a non-woven fiber material. The dispersion 4 preferably penetrates the reinforcement 3, in particular between the fibers of the non-woven fiber material. The dispersion 4 can penetrate the reinforcement 3 completely, i.e., up to the opposite surface of the reinforcement 3.

[0138] The reinforcement 3 is preferably a thin sheet material produced by mechanical or chemical processing of discontinuous fibers, preferably in the form of paper with or without additional holes in it. The dispersion 4 preferably penetrates the reinforcement 3, in particular between the fibers of a paper. The dispersion 4 can completely penetrate the reinforcement 3, i.e., reach the opposite surface of the reinforcement 3 and be bonded to the first substrate 1 and the second substrate 7.

[0139] The colloidal aqueous dispersion 4, comprising an alkali metal hydrosilicate, can be prepared according to the method described herein, in particular by carrying out the steps of:

[0140] • Comminution of porous silicon dioxide raw materials to a particle size that provides a specific surface area of ​​the material in the range of 0.05-0.5 m² 2 / grams

[0141] • Dosage of this raw material and air-dried granulated alkali metal hydroxide,

[0142] • Irrigation in the reactor and mixing under self-heating until a hot semi-finished product is obtained,

[0143] • Unloading the hot semi-finished product into a container and storing this semi-finished product in the container until a homogeneous colloidal aqueous dispersion of the alkali metal hydrosilicate is obtained.

[0144] The resulting colloidal aqueous dispersion 4 of an alkali metal hydrosilicate can be applied directly from the aforementioned container to the first substrate 1 or transferred and / or temporarily stored beforehand.

[0145] However, it is not ruled out that the dispersion 4 used in Fig. 1, or the dispersion 4 of the alkali metal hydrosilicate of the inventive fire protection system, can be produced in other, possibly less advantageous ways in order to be usable for the fire protection system. In other words, the described manufacturing process for dispersion 4 is preferred.

[0146] Fig. 2 illustrates the use of the fire protection system on a protected element 9. First, the packaging of the roll 5 produced in Fig. 1 or any other packaging unit is removed (not shown). The protected element 9 can be a container or an enclosure, with the fire protection system being attached to the inside of the protected element in the form of a hollow body. The container or enclosure can be made of metal. The fire protection system can be used to contain, delay, or extinguish a fire in the container or enclosure.

[0147] The element 9 to be protected can be the inner and / or outer surface of a housing or a shield, for fire protection in front of or for objects located in or behind it.

[0148] One of the substrates 1 or 7, for example, the second substrate 7 as shown, is detached from the dispersion 4, and the now exposed reinforcement 3 with the dispersion 4 adhering to it is pressed onto the surface of the element 6. While continuously peeling off the second substrate 7, the dispersion 4 and reinforcement 3 are applied further along the surface. The second of the two substrates 1 or 7, for example, the first substrate 1 as shown, can remain on the outside of the element 9 to be protected. Preferably, only one layer is applied. If a second layer is applied, the substrate 1 or 7 that is on the outside of the first layer can be peeled off beforehand. Since the reinforcement 3 is preferably penetrable by the dispersion 4, two superimposed layers of the dispersion 4 bond through the intervening reinforcement 3. This results in particularly good adhesion between the layers.

[0149] In another variant, the next layer is applied to the outer substrate 1 or 7 of the first layer.

[0150] Once the packaging, especially vacuum packaging, has been removed from the roll 5 or other packaging unit, the dispersion 4 begins to harden, allowing sufficient time for the application of the fire protection system. Thus, the dispersion 4 hardens after application to the surface of the element 6 to be protected.

[0151] To accelerate curing on the surface, the substrate 1 or 7 remaining on the outside of the surface can be permeable to air, or made permeable to air after application.

Claims

Patent claims 1. Method for manufacturing a fire protection system, comprising: Dosage of a crushed silicon dioxide raw material and a granulated alkali metal hydroxide into a reactor; Adding water to the reactor and mixing under self-heating until a hot semi-finished product is obtained; Storage of this semi-finished product until a homogeneous colloidal aqueous dispersion (4) of the alkali metal hydrosilicate is obtained; Application of the homogeneous colloidal aqueous dispersion (4) onto a substrate (1); Applying a reinforcement (3) to the substrate (1) or the dispersion (4) according to the order of applying the dispersion (4) and the reinforcement (3); Applying another substrate (7) over the dispersion (4) and the reinforcement (3), pressing or hot pressing the fire protection system into a three-dimensional shape and / or into a rigid object.

2. Method according to claim 1, characterized in that the fire protection system is applied to a surface or element (9) to be protected in two steps, wherein in the first step the fire protection system is transformed into a rigid object by pressing or hot pressing and in the second step the rigid object is applied or glued onto the surface or element (9) to be protected.

3. Method according to claim 2, characterized in that the conversion into a rigid object is carried out by partially drying the dispersion (4).

4. Method according to one of claims 1 to 3, characterized in that the pressing or hot pressing of the fire protection system takes place in a mold, wherein the fire protection system has the first substrate (1) and the second substrate (7) during the pressing or hot pressing, between which the colloidal aqueous dispersion (4) of the alkali metal hydrosilicate and at least one layer of the reinforcement (3) is present.

5. The method of claim 4, characterized in that several layers of the fire protection system are placed in a mold, with one of the following measures: a separating film is provided between the layers, or no separating film is provided between the layers, or - A perforated or cut-out separating film is placed between the layers.

6. Method according to one of claims 1 to 5, characterized in that the fire protection system is attached to an element (9) to be protected by pressing or hot pressing, preferably by pressing the element into a housing which serves as a mold.

7. Method according to claim 6, characterized in that the dispersion (4) or the reinforcement (3) is free during pressing or hot pressing on the side facing the element (9) to be protected, by removing a substrate (1, 7).

8. Method according to one of claims 1 to 7, characterized in that at least one of the substrates (1, 7) is a material that can be plastically deformed by pressing.

9. Method according to one of claims 1 to 8, characterized in that at least one of the substrates (1, 7) is a metal sheet, deep-drawing sheet or a thermoplastic plastic film, deep-drawing film or thermoforming film.

10. Method according to one of claims 1 to 7, characterized in that the dispersion (4) is applied to a substrate (1) in the form of a separating film, wherein the substrate (7) is also in the form of a separating film (7).

11. Method according to one of claims 1 to 10, characterized in that the reinforcement (3) in the form of at least one layer of a flexible sheet structure of a non-woven fiber material is placed under, in or on the dispersion (4).

12. Method according to any one of claims 1 to 11, characterized in that the ratio of the mass of the layer of dispersion (4) of alkali metal hydrosilicate and the mass of the reinforcement (3) is in the range of 30:1 to 6:1, in particular 30:1 to 11:

1.

13. Method according to one of claims 1 to 12, characterized in that a strip of the fire protection system is formed into a rigid object by partial drying during hot pressing.

14. Method according to any one of claims 1 to 13, characterized in that the fire protection system is packaged airtight or vacuum-packed as long as the dispersion (4) is liquid or at least not completely dry.

15. Method according to claim 14, characterized in that the pressing or hot pressing takes place before the fire protection system is hermetically sealed or vacuum-packed, or after the hermetically sealed packaging has been removed.

16. Method according to one of claims 1 to 15, characterized in that one of the substrates (1, 7) on which the dispersion (4) of the alkali metal hydrosilicate is present remains on the surface to be protected after application to it.

17. Method according to any one of claims 1 to 16, characterized in that the curing of the dispersion (4) is carried out in two steps, wherein in a first step a shaping is carried out in which the two-dimensional fire protection system is hot-pressed with a is given a three-dimensional shape and in a second step the three-dimensional fire protection system is attached to a surface or element to be protected (9).

18. Method according to any one of claims 1 to 16, characterized in that the dispersion (4) is cured in two steps, wherein in a first step the fire protection system is transformed into a rigid object under partial drying and in a second step the three-dimensional fire protection system is applied to a surface or element (9) to be protected, where further drying to a hard gel takes place.

19. Ready-to-use fire protection system comprising a dispersion (4) of an alkali metal hydrosilicate and at least a first substrate (1) and a second substrate (7) between which the dispersion (4) and at least one layer of reinforcement (3) are located, characterized in that the fire protection system is produced by pressing or hot pressing with a three-dimensional shape and / or as a rigid object.

20. Ready-to-use fire protection system according to claim 19, characterized in that it is packaged airtight or vacuum-packed.

21. Ready-to-use fire protection system according to claim 19 or 20, characterized in that the reinforcement (3) comprises at least one layer of a flexible sheet structure of a non-woven fiber material.

22. Ready-to-use fire protection system according to claim 21, characterized in that the reinforcement (3) is a fleece or paper which is permeable by the dispersion (4).

23. Ready-to-use fire protection system according to claim 21 or 22, characterized in that flexible surface structures are provided with holes which are present in addition to any interfiber spaces of the non-woven fiber material.

24. Ready-to-use fire protection system according to one of claims 19 to 23, characterized in that the first substrate (1) and the second substrate (7) are each a separating film which is dense to the dispersion (4).

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