Flame retardant matrix

Abstract

The present invention relates to fire retardant compositions, and fire retardant objects formed therefrom comprising a preformed gas-producing material and a matrix, wherein, in use, the gas-producing material prevents, limits or reduces combustion of the matrix. Also disclosed are methods of producing fire retardant compositions, methods of making objects formed therefrom as well as structures having fire retardant properties.

Claims

1. A fire retardant material comprising a preformed gas-producing material admixed with a matrix, wherein the preformed gas-producing material comprises: a) a comminuted foamed polymer; b) a nitrogen-containing fuel; and c) an oxidiser.

2. A fire retardant material according to claim 1, wherein the comminuted foamed polymer of the preformed gas-producing material is selected from at least one member of a group consisting of phenolic resin foams, polystyrene foams, polyurethane foams, polyvinylchloride foams, polyester foams, polyether foams, and foam rubber.

3. A fire retardant material according to claim 1, wherein the comminuted foamed polymer of the preformed gas-producing material is open-cell.

4. A fire retardant material according to claim 1, wherein the nitrogen-containing fuel of the preformed gas-producing material is selected from at least one member of a group consisting of guanidine salts, triazoles, tetrazoles, and azo-compounds.

5. A fire retardant material according to claim 1, wherein the oxidiser of the preformed gas-producing material is selected from at least one member of a group consisting of alkali metal nitrates, perchlorates, and carbonates.

6. A fire retardant material according to claim 1, wherein the preformed gas-producing material comprises the comminuted foamed polymer, the nitrogen-containing fuel, and the oxidiser in the following amounts: comminuted foamed polymer between about 5 to 35% by weight; nitrogen-containing fuel between about 5 to 45% by weight; and oxidiser between about 30 to 75% by weight.

7. A fire retardant material according to claim 1, wherein the comminuted foamed polymer, the nitrogen-containing fuel, and the oxidiser of the preformed gas-producing material are in particulate form.

8. A fire retardant material according to claim 7, further comprising at least one member of a group consisting of comminuted foam polymer having an average particle size of 1 to 200 m, nitrogen-containing fuel having an average particle size of 5 to 150 m, and oxidiser having an average particle size of 1 to 100 m.

9. A fire retardant material according to claim 7, wherein the mixture of the comminuted foamed polymer, the nitrogen-containing fuel, and the oxidiser particles are in an aggregated form.

10. A fire retardant material according to claim 1, wherein at least 60 wt % of the preformed gas-producing material is the comminuted foamed polymer, the nitrogen-containing fuel, and the oxidiser.

11. A fire retardant material according to claim 1, wherein the matrix is a polymeric material or a bitumous material.

12. A fire retardant material according to claim 11, wherein the polymeric material is selected from at least one member of a group consisting of a brominated polymer, polyethylene, polyimide, polyurethane, polybenzimidazole, polybenzoxazole, polybenzthiazole, polysialate, and a phenolic resin.

13. A fire retardant material according to claim 11, wherein the bitumous material is based on at least one member of a group consisting of atactic polypropylene (APP), amorphous poly alpha olefin (APAO), thermoplastic polyolefin (TPO), styrene-butadiene-styrene (SBS), styrene-ethylene-butadiene-styrene (SEBS), and synthetic rubber.

14. A fire retardant material according to claim 1, wherein the matrix further comprises at least one fire suppressant selected from at least one member of a group consisting of bismuth, antimony, antimony trioxide, chlorinated paraffins, brominated polymers, phosphoric acid esters, polyphosphoric acid ammonium, magnesium hydroxide, aluminium hydroxide, and zinc borates.

15. A fire retardant material according to claim 1, wherein the preformed gas-producing material is admixed with the matrix in amounts of up to 85% by weight of the matrix.

16. A fire retardant material according to claim 1, wherein the preformed gas-producing material is present in a homogeneous distribution throughout the matrix.

17. A fire retardant composite comprising a substrate bonded to a layer of polymeric material, and further comprising a preformed gas-producing material, admixed with the polymeric material and/or the substrate; wherein the preformed gas-producing material comprises a comminuted foamed polymer, a nitrogen-containing fuel, and an oxidiser.

18. A fire retardant composite according to claim 17, wherein the preformed gas-producing material is within the matrix of the polymeric material and the substrate.

19. A composite material according to claim 17, wherein the polymeric material is a sheet moulding compound (SMC).

20. A composite material according to claim 17, wherein the preformed gas-producing material is homogeneously distributed throughout the polymeric material.

21. A composite material according to claim 17, wherein the substrate is a foamed polymer resin selected from at least one member of a group consisting of phenolic resin foams, polystyrene foams, polyurethane foams, polyvinylchloride foams, polyester foams, polyether foams, and foam rubber.

22. A composite material according to claim 21, wherein the preformed gas-producing material is present within the matrix of the polymeric material.

23. A wall panel, ceiling panel, floor panel, cladding, or partition panel comprising a fire retardant material comprising a preformed gas-producing material admixed with a matrix, wherein the preformed gas-producing material comprises a comminuted foamed polymer, a nitrogen-containing fuel, and an oxidiser.

24. A table, chair, vase, shelves, cupboard, or part thereof, comprising a fire retardant material comprising a preformed gas-producing material admixed with a matrix, wherein the preformed gas-producing material comprises a comminuted foamed polymer, a nitrogen-containing fuel, and an oxidiser.

25. A tile comprising a fire retardant material comprising a preformed gas-producing material admixed with a matrix, wherein the preformed gas-producing material comprises a comminuted foamed polymer, a nitrogen-containing fuel, and an oxidiser.

Description

(1) The present invention will now be described by way of example and with reference to the accompanying drawings in which:

(2) FIG. 1 is a diagrammatic cross-section of a fire retardant material in accordance with the present invention, wherein the gas-producing material is homogeneously distributed throughout the matrix;

(3) FIG. 2 is a diagrammatic cross-section of a fire retardant material in accordance with the present invention, wherein one side of the matrix contains a higher concentration of gas-producing material;

(4) FIG. 3 is a diagrammatic cross-section of a fire retardant material in accordance with the present invention, wherein the gas-producing material is at a higher concentration around the periphery of the polymer matrix;

(5) FIG. 4 is a diagrammatic cross-section of a composite material for use in fire suppression in accordance with the present invention; and

(6) FIG. 5 is a diagrammatic representation of the layers present when moulding a composite material in accordance with the present invention.

(7) Looking at FIGS. 1 to 3, there is a fire suppression material (10) comprising a matrix (12) and a gas-producing material (14).

(8) In the present example, the matrix (12) is a polymer, such as polyurethane. A gas-producing material (14) is admixed with the polymer matrix (12). In the present example, the gas-producing material (14) has been admixed with the polymer matrix (12) whilst the polymer matrix is in a liquid state.

(9) In the example of FIG. 1, the fire retardant material is in the form of a film or sheet.

(10) It can be seen that the gas-producing material is distributed homogeneously throughout the polymer matrix, as shown in FIG. 1.

(11) Alternatively, the gas-producing material (14) may be applied to a surface of a mould, preferably an aluminium mould. A layer of sheet-form polymeric matrix material (12) may then be applied to the mould covering the gas-producing material (14). Upon applying pressure to the layers (such as described above), the gas-producing material (14) becomes embedded in the surface of the polymer matrix (12). The fire retardant material resulting comprises a polymer matrix (12) having a higher concentration of gas-producing material (14) at one surface (as shown in FIG. 2).

(12) Alternatively, a layer of sheet-form polymer matrix material (12) can be applied directly to the mould surface, and a gas-producing material (14) subsequently applied on top of the sheet-form polymer matrix material. Upon the application of pressure to the layers the gas-producing material (14) becomes embedded in the matrix material (12).

(13) In a further alternative method, the gas-producing material is applied both directly to the surface of the mould and on top of the sheet-form polymer matrix material (12) before the application of pressure. In this way, the resulting fire retardant material comprises a polymer matrix material (12) containing gas-producing material (14) around the periphery of the polymer matrix.

(14) The fire retardant materials of FIGS. 1 to 3 further comprise fibers (16) located within the polymer matrix (12) so as to increase the strength and rigidity of the structure. It will be appreciated that such fibres can be provided in the form of a layer within the polymer matrix material (12) and may be woven or non-woven such as described above. Such disclosure is particularly relevant to the use of SMC, again as described above.

(15) FIG. 4 illustrates a composite (20) comprising a sheet-form polymeric material (22) and a substrate (24), wherein the sheet-form material is preferably sheet moulding compound (SMC).

(16) The matrix layer (22) is admixed with the gas-producing material (26), wherein admixing has been performed as described above. The substrate (24) is a foamed phenolic resin, which is open-cell (28) in nature.

(17) The composite of FIG. 4 may be prepared using a method such as shown in FIG. 5 and as described below. In FIG. 5, a layer of sheet-form polymer matrix material (32) is applied to a surface of a mould (36) over a gas-producing material (34), which material is pre-applied to the mould as a first step (it will be appreciated that the layer of polymer matrix material could be pre-mixed with the gas-producing material and applied as a single layer of mixed material). The sheet-form polymer matrix (32) is preferably sized so as to extend across the whole area of the mould surface (36).

(18) It will be appreciated that in FIG. 5 and in other of the figures the shapes of the components are shown schematically. In particular, the relative thicknesses of the elements are not shown to scale. For the present example, the preferred thickness of the matrix layer is about 1 mm whereas the thickness of the substrate is about 5 cm.

(19) A block of open-celled foam substrate (40) (in the present example, the foam used has a cell size range of 0.5 to 3 mm and a density of 100 to 500 kg/m.sup.3) is placed on the sheet-form polymer matrix material (32) (again, it will be appreciated that the layers could be applied in the reverse order). The materials are then pressed and preferably heated (42), so as to produce a monolithic composite structure. The heating is preferably to a temperature greater than about 100 C., preferably greater than 120 C.

(20) By using an open-cell foam, it is possible for the sheet-form polymer matrix material to flow into the open-cells of the substrate thereby forming a strong bond. In addition, the heating of the mould can be used to commence the curing process of the sheet-form polymer matrix material (32), and therefore the process also may comprise the step of causing or allowing the material to cure.

(21) In addition, although not shown, the process may comprise the step of providing a veil between the matrix material and a surface of the mould. It will be appreciated that where gas-producing material is placed on the mould, the veil is preferably between the matrix material and the gas-producing material, and the mould, so as to provide a smooth surface finish. Preferably, the veil is substantially pervious to a component of the polymer matrix during the moulding.

(22) In addition, although not shown, a further layer of polymeric matrix material may be applied to an opposing surface of the substrate, the application of pressure sandwiching the substrate between the two layers of material.

(23) The polymeric matrix material may include reinforcing fibres, such as a mat, fabric of fibres, a mesh or network of fibres. By way of example, the polymeric matrix material may comprise one or more of carbon fibres, glass fibres and aramid fibres.

(24) As noted above, in a preferred embodiment, the polymeric matrix material comprises SMC (sheet moulding compound).

(25) Whichever polymeric matrix material is chosen, it is preferable for the viscosity of the material to reduce during the pressing step.

(26) In the example described herein, the polymeric material is applied as a substantially single thickness. It will however be appreciated that multiple layers could be used.

(27) Further, where required, additional layers of reinforcing fibres can be included between the substrate and the layer of polymeric matrix material.

(28) In the process shown in FIG. 5, near the heated mould surface (36), the SMC begins to liquefy and flows into cells at the surface of the substrate (40) as well as around the preformed gas-producing material.

(29) Air and other gases trapped between the SMC layer (32) and the substrate (40) passes through the open cell structure of the foam. The components may be held in the mould for a sufficient time for the SMC to cure for form a hard, cured skin bound to the moulded substrate.

(30) In FIG. 5, both an upper and lower portion of the mould (36) are profiled, however it is not essential for there to be any shaping to the mould, and thus press plates and/or heated press plates will suffice.

(31) Gas Producing Material Examples

(32) A series of measurements on the reaction smoke generated from three types of gas-producing material were conducted. The three types of gas-producing material were:

(33) A. Prior Art Material with catalyst comprising potassium nitrate, phenol-formaldehyde resin, toluenesulfonic acid, dicyandiamide

(34) B. Prior Art Material without catalyst comprising Potassium Nitrate, phenol-formaldehyde resin, dicyandiamide

(35) C. Inventive Material comprising: potassium nitrate, dicyandiamide, comminuted foamed phenol-formaldehyde resin

(36) The prior art materials are marketed by Villanova and sold as part of a product known as Firestryker. The Prior Art Material with catalyst comprises, by total weight of the composition, potassium nitrate in an amount of 60%, phenol-formaldehyde resin in an amount of 13.73%, toluenesulfonic acid in an amount of 1.29%, dicyandiamide in an amount of 23.46% and water in an amount of 0.86%.

(37) The evaluation of the reaction smoke generated from the three types of gas-producing material was carried out for a period of two hours inside a closed cabin of a volume of 7.7 m3. For the Prior Art Material without catalyst, three charges, each weighing 50 kg, were combusted over a period of two hours. The charges were ignited at intervals of 40 minutes, i.e. the first charge was ignited at the beginning of the two hour period, the second charge 40 minutes into the period, and the third charge an hour and twenty minutes into the period. For the Prior Art Material with catalyst and the Inventive Material, four charges, each weighing 50 kg, were combusted over two hours. The charges were ignited at intervals of 30 minutes, i.e. the first charge was ignited at the beginning of the two-hour period, the second charge 30 minutes into the period, the third charge an hour into the period, and the final charge an hour and a half into the period.

(38) Measurement probes were located inside a small hole inside the cabin.

(39) Measurements were taken on the following pollutants: Combustion gas: CO, NOx, SOx (like SO2), O2 Phenol Formaldehyde Ammonia Total cyanide (Hydrogen cyanide and salt) Hydrogen sulfide Polynuclear aromatic hydrocarbons
Analytic Methods

(40) Measurements relating to the combustion gas pollutants were carried out for a period of 20 minutes after combustion of the first charge. All other measurements were carried out for the duration of the two hour period.

(41) Combustion Gas: CO, NOx, SOx (like SO2), O2

(42) The combustion parameters were measured continuously. A portable meter HORIBA with NDIR detection system was used for measuring CO and SO2, chemiluminescence was used for measuring NOx, and paramagnetism was used for measuring O2

(43) Total Cyanide (Hydrogen Cyanide and Salt)UV-VISInner Method (Rif. Met. Uff. MU 2251:2008+ISO 6703-2:1984)

(44) Hydrogen cyanide measurements were conducted using NaOH water solutions as measuring supports. The NaOH solutions were contacted with pyridine and barbituric acid, and then analysed using US-VIS spectrophotometry at a wavelength of 578 nm.

(45) PhenolGC-MSMet. Uff. NIOSH 2546 1994

(46) Phenol measurements were conducted using XAD-7 solid sorbent tubes as measuring supports. The solid sorbent tubes were eluted with methanol. Analysis was carried out using a gas chromatography mass detection system.

(47) FormaldehydeHPLC-UVMet. Uff. NIOSH 2016 1998

(48) Formaldehyde measurements were conducted using cartridges containing silica gel coated with 2,4-dinitrophenylhydrazine as measurement supports. The cartridges were eluted with a solution of acetonitrile for HPLC. Analysis was carried out using liquid chromatography at high pressure (HPLC-UV) with a UV-VIS detecting system.

(49) Polynuclear Aromatic HydrocarbonsGC-MSMet. Uff. NIOSH 5515 1994

(50) Measurements were conducted using XAD-2 vials in series with glass fiber filters as measurement supports. The filters and vials were eluted in a hexane-acetone mixture. The obtained solutions were analyzed using a gas chromatography mass detection system.

(51) AmmoniaUV-VISMet. Uff. NIOSH 6015 1994

(52) Ammonia measurements were conducted using solid sorbent tubes with silica gel activated with sulfuric acid as measurement supports. The supports were eluted with a solution of ultrapure water. The obtained solutions were analyzed with UV-VIS spectrophotometry.

(53) Hydrogen SulfideICMet. Uff. NIOSH 6013 1994

(54) Hydrogen sulfide measurements were conducted using solid sorbent tubes with coconut shells as measurement supports. The solid sorbent tube were eluted with a solution of NaOH. The obtained solution was analyzed using ionic chromatography.

(55) A glass fiber filter was used for the measurements that require the use of a solid sorbent tube, so as to avoid the packing of the absorbent layer by particulate matter produced during combustion. The filter was also analysed.

(56) Results

(57) Combustion gas: CO, NOx, SOx (like SO2), O2:

(58) The measurements do not show any important differences between the combustion gases omitted by gas-producing materials. The combustion gases were produced in similar amounts by each material, except for NOx and CO which were produced in slightly slower amounts by the Prior Art Material with catalyst.

(59) TABLE-US-00001 Sample 12SP0234- 12SP0234- 12SP0234- 002 023 034 Typology Without Own Milan Catalyst Production Extinguisher Extinguisher Emission Date 17 Feb. 2012 17 Feb. 2012 17 Feb. 2012 Parameter U.M. Value Value Value CO mg/m3 100.5 86.9 108.3 NOx (come mg/m3 29.4 26.3 29.11 NO2) O2 % 20.8 20.8 20.8 SO2 mg/m3 7.5 8.1 9.2
Phenol:

(60) The Prior Art Material without catalyst produced less phenol on combustion than the other materials. The absence of a toluenesulfonic acid catalyst used for crosslinking of the phenol-formaldehyde resin during preparation of the Prior Art Material without catalyst meant that cross-linking was carried out for a longer time, thereby allowing unreacted phenol to disperse into the atmosphere. Thus, there is less phenol to be released on combustion of the Prior Art Material without catalyst. As the resin in the Inventive Material is pre-foamed, the phenol has had some time to disperse from the foam into the atmosphere. Thus, the resin can be considered old in comparison to the resin used in the Prior Art Material with catalyst.

(61) TABLE-US-00002 Sample 12SP0234- 12SP0234- 12SP0234- 002 023 034 Typology Without Own Milan Catalyst Production Extinguisher Extinguisher Emission Date 15 Feb. 2012 21 Feb. 2012 21 Feb. 2012 Parameter U.M. Value Value Value Phenol mg/m3 0.066 31 4.8
Formaldehyde:

(62) The formaldehyde values are low in each of the gas-producing materials.

(63) TABLE-US-00003 Sample 12SP0234- 12SP0234- 12SP0234- 006 024 035 Typology Without Own Milan Catalyst Production Extinguisher Extinguisher Emission Date 15 Feb. 2012 21 Feb. 2012 21 Feb. 2012 Parameter U.M. Value Value Value Formalde- mg/m3 <0.006 <0.006 <0.006 hyde
Ammonia:

(64) The ammonia values are similar in the three types of material, taking into account the quantities of charges used for the test and the nature of the analyses.

(65) TABLE-US-00004 Sample 12SP0234- 12SP0234- 12SP0234- 003 021 019 Typology Without Own Milan Catalyst Production Extinguisher Extinguisher Emission Date 15 Feb. 2012 21 Feb. 2012 21 Feb. 2012 Parameter U.M. Value Value Value Ammonia mg/m3 0.5173 1.03 1.77
Polynuclear Aromatic Hydrocarbons:

(66) The results show that polynuclear aromatic hydrocarbons are produced from organic components in the materials during combustion. The Inventive Material generated, on average, smaller quantities of polynuclear aromatic hydrocarbons compared to the other two materials. Without wishing to be bound by any theory, it is believed that the smaller quantities measured could be as a result of the higher combustion temperature of the Inventive Material causing greater decomposition of the polynuclear aromatic hydrocarbons.

(67) TABLE-US-00005 Sample 12SP0234- 12SP0234- 12SP0234- 004 021 031 Typology Without Own Milan Catalyst Production Extinguisher Extinguisher Emission Date 15 Feb. 2012 21 Feb. 2012 21 Feb. 2012 Parameter U.M. Value Value Value Naphthalene Ng/m3 786 16861 10180 Acenaphthylene Ng/m3 1099 6789 5837 Acenaphthene Ng/m3 292 58.3 257 Fluorene Ng/m3 484 1669 790 Phenanthrene Ng/m3 4054 14169 4940 Anthracene Ng/m3 877 2494 820 Fluoranthene Ng/m3 1434 3269 1150 Pyrene Ng/m3 614 1267 533 Benzo(a)anthra- Ng/m3 801 1744 340 cene Chrysene Ng/m3 1386 2633 417 Benzo(b)fluoran- Ng/m3 451 764 185 thene Benzo(k)fluoran- Ng/m3 437 569 207 thene Benzo(a)pyrene Ng/m3 412 1392 453 Benzo(e)pyrene Ng/m3 376 828 263 Perylene Ng/m3 43.3 103 23.3 Indeno(1,2,3- Ng/m3 94.4 133 33.3 cd)pyrene Dibenz(a,h)anthra- Ng/m3 141 211 36.7 cene Benzo(g,h,i)pery- Ng/m3 274 408 61.7 lene Dihenz(a,l)pyrene Ng/m3 83.3 283 40 Dibenz(a,e)pyrene Ng/m3 82.2 161 25.3 Dibenz(a,i)pyrene Ng/m3 45 150 20.7 Dibenz(a,h)pyrene Ng/m3 25.6 72.2 18
Hydrogen Sulphide:

(68) The Prior Art Material without catalyst produced a minor amount of hydrogen sulfide (H2S), very likely due to the absence of toluenesulfonic acid used as a catalyst. The Inventive Material produced more hydrogen sulphide than the Prior Art Material with catalyst. This is somewhat expected from given the relative amounts of sulphur present in the mixtures before combustion, shown below along with the amounts of certain other components.

(69) TABLE-US-00006 Sample 12SP0234- 12SP0234- 12SP0234- 005 020 030 Typology Without Own Milan Catalyst Production Extinguisher Extinguisher Emission Date 15 Feb. 2012 21 Feb. 2012 21 Feb. 2012 Parameter U.M. Value Value Value Hydrogen mg/m3 0.394 1.096 1.841 sulfide (H2S) Sample 12SP0234- 12SP0234- 12SP0234- 016 017 018 Typology Without Own Milan Catalyst Production Extinguisher Extinguisher Emission Date 21 Feb. 2012 21 Feb. 2012 21 Feb. 2012 Parameter U.M. Limit Value Value Value Total Bromine % <0.01 <0.01 <0.01 Total Chlorine % 0.09 0.16 0.11 Total Fluorine % 0.01 0.02 0.02 Total Iodine % <0.01 <0.01 <0.01 Total Sulphur % 0.02 0.1 0.35
Total Cyanide (Hydrogen Cyanide and Salt):

(70) A large difference can be seen between the cyanide produced on combustion of the Inventive Material and the prior art materials. The Inventive Material emits an amount of cyanide that is over ten times smaller than that emitted by the prior art materials, thereby allowing a much greater amount of gas-producing material to be used per unit of confined space. Without wishing to be bound by any theory, it is believed that small value observed in connection with the Inventive Material could be attributable to a higher temperature of combustion i.e. over 1000 C. versus less than 800 C.

(71) TABLE-US-00007 Sample 12SP0234- 12SP0234- 12SP0234- 007 019 019 Typology Without Own Milan Catalyst Production Extinguisher Extinguisher Emission Date 15 Feb. 2012 21 Feb. 2012 21 Feb. 2012 Parameter U.M. Value Value Value Total Cyanide mg/m3 76.7 48.4 3.16 (HCN and Salt)

(72) As can be seen from the experimental evidence, the gas-producing materials are suitable for suppressing fire, particularly in confined spaces where the potential accumulation of unwanted by-products can be harmful to humans. The results also show that the use of a comminuted foamed polymer leads to a reduction in cyanide emissions from a gas-producing material comprising a nitrogen-containing fuel and an oxidiser.

(73) Examples of Fire Retardant Materials

(74) Procedure

(75) The flame retardant abilities of the composite materials described above were tested by heating one side of the material with a flame for 30 seconds followed by a rest period of 20 seconds, wherein the material was not heated. The process of heating the composite material and rest periods was repeated thirteen times sequentially. Each panel tested had a thickness of 9 mm.

(76) 1. A panel formed of SMC and alumina

(77) A panel comprising 100 parts resin to 150 parts alumina was formed. The fire retardant properties of a panel formed from SMC and alumina was tested as described above. After being exposed to thirteen cycles of heating with a flame and resting, fire damage was observed throughout the panel, with the flame having burnt through from one side of the panel to the other.

(78) 2. A panel formed of an SMC layer containing 130 parts alumina and 20 parts of ground phenolic foam.

(79) A panel comprising 100 parts resin, 130 parts alumina and 20 parts of ground phenolic foam was formed. After being exposed to thirteen cycles of heating and resting, fire damage was observed throughout the panel, the flame having burnt through from one side to the other. However, it was observed that the time required for the fire to burn through the panel was three times longer compared to the panel of Example 1.

(80) 3. A panel formed of an SMC layer containing 130 parts alumina and 20 parts of the gas producing material described and exemplified above.

(81) A panel comprising 100 parts resin, 130 parts alumina and 20 parts gas producing material was formed. Upon exposing the panel to a flame, it was observed that the fire retarding material of the invention was able to extinguish the flame within 14 seconds of being exposed, for each of the thirteen cycles within the test. In this way, there was no significant ingress of the flame into the panel, and therefore the panel remained substantially intact after the testing was completed.

(82) The results above clearly demonstrate significant advantages in using the fire retardant materials of the present inventions, without which resulted in serious fire damage.