Intumescent card

Abstract

A fire-resistant liner comprising a central layer of card having adhered to each side, a layer of cloth coated or impregnated with an intumescent material.

Description

INTUMESCENT CARDFIELD OF THE INVENTION

[0001] The present invention relates to an intumescent card or liner. More especially, the invention concerns a card or sheet material lined with an intumescent layer for use as a fire-resistant barrier in building construction.BACKGROUND TO THE INVENTION

[0002] Fireproofing in building construction is essential for protecting occupants, limiting the spread of fire and reducing structural damage in the event of a fire. Fire protection measures must comply with local regulations, such as Approved Document B in the UK, which mandates rigorous fire safety standards in both new developments and existing buildings.

[0003] Conventional fire-resistant systems typically utilise materials such as concrete, gypsum-based boards, mineral wool insulation and various fire-resistant coatings.

[0004] Standard building materials, such as wood, timber panels, composite boards and plasterboard, may be enhanced through the application of a fire-resistant coating, such as an intumescent paint or fire-retardant surface treatment. The Applicant is a market leader in intumescent coatings and related passive fire protection technologies.

[0005] However, conventional intumescent paints and coatings can be difficult to apply consistently, often requiring multiple coats to achieve the necessary thickness. Their performance can be compromised by cracking, flaking or delamination over time, particularly on flexible or uneven substrates, and they may be sensitive to environmental factors such as moisture or impact. These limitations can make intumescent paints alone unsuitable or impractical in certain applications, especially in retrofit scenarios where surface preparation, curing times and disruption must be minimised.

[0006] Hence, achieving the required fire-resistance standards frequently necessitates the use of multilayered or heavy composite systems, which increase the overall size, weight and installation complexity of building components. Retrofitting existing structures to comply with updated standards can be particularly challenging, as conventional fireproofing solutions may require complete replacement of panels, linings or structural elements rather than simple augmentation.

[0007] The present invention seeks to provide a thin, lightweight fire-resistant barrier that functions as a fire protective liner without significantly increasing the thickness or mass of the structural element to which it is applied.STATEMENT OF THE INVENTION

[0008] According to a first aspect of the invention, there is provided a fire-resistant liner comprising a core layer formed of card and a cloth layer adhered to each side of the core layer, wherein each cloth layer is coated or impregnated with an intumescent material.

[0009] The core layer may comprise paper card, cardboard, fibreboard, polymeric sheet materials or a multilayer laminated card.

[0010] Preferably, each cloth layer comprises a nylon cloth and is impregnated with graphite powder and / or coated with an intumescent coating, such as an intumescent paint.

[0011] Preferably, the cloth layers are adhered to the core layer using a heat-resistant adhesive, which may contain or be impregnated with an intumescent additive.

[0012] According to a second aspect of the invention, there is provided a method of manufacturing a fire-resistant liner, the method comprising: providing a core layer of card; coatingor impregnating a cloth material with an intumescent material to form coated cloth layers; and adhering a coated cloth layer to each side of the core layer using an adhesive.

[0013] The method may further comprise coating the core layer with an intumescent material prior to adhering the cloth layers, and the adhesive may contain an intumescent additive. The finished liner may be cut into sheets or strips or formed into a roll.

[0014] There is provided a fire-resistant barrier for use in construction of buildings or similar structures, the barrier comprising a sheet or strip of card lined on both sides with a nylon cloth layer coated or impregnated with an intumescent material.BRIEF DESCRIPTION OF DRAWINGS

[0015] An embodiment of the invention will now be described, by way of example only, with reference to the accompanying figures, in which:

[0016] Figure 1 is a top plan view of a fire-resistant liner constructed in accordance with the invention; and

[0017] Figure 2 is a side cross-sectionalviewof the liner of Figure 1.DETAILED DESCRIPTION OF THE INVENTION

[0018] Figures 1 and 2 illustrate a strip of fire-resistant liner in accordance with an embodiment of the present invention.

[0019] As shown in Figure 2, the liner comprises a composite sheet including a central layer of card 2 sandwiched between two outer layers of cloth material 4.

[0020] Although a central layer of paper card 2 is preferred, alternative core materials may be used, such as cardboard, fibreboard, polymeric sheet materials or multilayer laminated card.

[0021] Preferably, the cloth layers 4 are formed from 440 g / m2nylon cloth. However, other suitable fabrics may be employed, such as polyurethane-based textiles or other flexible textile substrates capable of retaining an intumescent coating.

[0022] Each cloth layer 4 is impregnated or coated with an intumescent material. The intumescent material may comprise, for example, graphite powder and / or a composition formulated to expand upon exposure to elevated temperatures.

[0023] A suitable intumescent material includes an intumescent paint, for example, those manufactured and marketed by the Applicant under the HW System brand.

[0024] In some embodiments, the central layer of paper card 2 may additionally be coated with an intumescent material, such as an intumescent paint, to further enhance the fire-resistant performance of the liner.

[0025] The cloth layers 4 are secured to each side of the paper card layer 2 using an adhesive (not shown). The adhesive may be a heat-resistant bonding agent and may also incorporate an intumescent additive to enhance the overall fire protection performance of the liner.

[0026] The intumescent cloth layers 4 cause the liner to be fire retardant by providing a barrier that expands under heat to protect the underlying substrate.

[0027] The resultant fire-resistant liner may be applied to a wide variety of building materials or surfaces using suitable adhesives or mechanical fixing means. As noted previously, any such adhesive may additionally contain an intumescent additive.

[0028] This combination of a rigid or semi-rigid core layer with intumescent treated cloth layers provides a balance of stability, flexibility and fire-resistant performance. The liner is particularly suitable for application to plasterboard walls or ceilings, offering a thin, lightweight and flexible fire barrier. Due to its rigidity and layered structure, the liner is unlikely to detach from the substrate during a fire.

[0029] The liner may be provided in sheet form and readily cut to any desired shape using standard cutting tools. It need not be restricted to strip form; for example, it may be produced in the form of wallpaper. The liner may also be wound into a roll for convenient storage and unrolled for application.

[0030] The liner may be used for a wide variety of fire protection applications, including walls, ceilings, service risers, duct enclosures, partition systems and refurbishment projects where a thin retrofittable fire barrier is required with minimal disruption.

Claims

CLAIMS1. A fire-resistant liner comprising a core layer formed of card and a cloth layer adhered to each side of the core layer, wherein each cloth layer is coated or impregnated with an intumescent material.

2. A liner according to claim 1, wherein the core layer comprises paper card, cardboard, fibreboard, polymeric sheet materials or a multilayer laminated card.

3. A liner according to claim 1, wherein each cloth layer comprises a nylon cloth.

4. A liner according to any preceding claim, wherein each cloth layer is impregnated with graphite powder.

5. A liner according to any preceding claim, wherein each cloth layer is coated with an intumescent coating.

6. A liner according to claim 5, wherein the intumescent coating comprises an intumescent paint.

7. A liner according to any preceding claim, wherein the cloth layers are adhered to the core layer using a heat-resistant adhesive.

8. A liner according to claim 7, wherein the adhesive contains or is impregnated with an intumescent additive.

9. A method of manufacturing a fire-resistant liner comprising:providing a core layer of card;coating or impregnating a cloth material with an intumescent material to form coated cloth layers; andadhering a coated cloth layer to each side of the core layer using an adhesive.

10. The method of claim 9, further comprising coating the core layer with an intumescent material before adhering the cloth layers.

11. The method of claim 9 and 10, wherein the adhesive used to adhere the cloth layers contains an intumescent additive.

12. The method of any of claims 9 to 11 , wherein the liner is cut into sheets, strips or formed into a roll.

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