Inorganic fire protection and insulation foam and use thereof

Abstract

A hydraulically binding composition can be used to produce an inorganic fire-protection and/or insulation foam. The composition includes: (i) a hydraulic binder, (ii) a blowing-agent mixture, (iii) a thermally expandable compound, and (iv) optionally a foam stabilizer, where the at least one thermally expandable compound, depending on a particle size thereof and an adjusted density of a foamed composition, is present in a quantity such that a foam structure of the foamed composition is not destroyed by expansion thereof during heating of the composition above an onset temperature thereof.

Claims

1. A hydraulically binding composition for producing an inorganic fire-protection and/or insulation foam, the composition comprising: (i) at least one hydraulic binder, (ii) a blowing-agent mixture, (iii) at least one thermally expandable compound, and (iv) optionally a foam stabilizer, wherein a content of said at least one thermally expandable compound is such that a foam structure of a foamed composition is not destroyed by expansion thereof during heating of the composition above an onset temperature of said thermally expandable compound.

2. The composition according to claim 1, wherein: the proportion of thermally expandable compound is between 0.5 and 25 wt % and a foam density is from 150 g/L to 300 g/L, or the proportion of thermally expandable compound is between 0.4 and 15 wt % and a foam density is from 300 g/L to 600 g/L, or the proportion of thermally expandable compound is between 0.3 and 10 wt % and a foam density is from 600 g/L to 800 g/L, in each case relative to the total composition.

3. The composition according to claim 1, wherein the at least one thermally expandable compound is at least one member selected from the group consisting of a graphite intercalation compounds and an expandable silicate material.

4. The composition according to claim 3, wherein the at least one thermally expandable compound is a graphite intercalation compound, and wherein: the proportion of the graphite intercalation compound is between 0.5 and 6 wt % and a foam density is from 150 g/L to 300 g/L, or the proportion of the graphite intercalation compound is between 0.4 and 5 wt % and a foam density is from 300 g/L to 600 g/L, or the proportion of the graphite intercalation compound is between 0.3 and 4 wt % and a foam density is from 600 g/L to 800 g/L, in each case relative to the total composition.

5. The composition according to claim 3, wherein the at least one thermally expandable compound is an expandable vermiculite, and wherein: the proportion of expandable vermiculite is between 1 and 25 wt % and a foam density is from 150 g/L to 300 g/L, or the proportion of expandable vermiculite is between 0.5 and 15 wt % and a foam density is from 300 g/L to 600 g/L, or the proportion of expandable vermiculite is between 0.4 and 10 wt % a foam density is from 600 g/L to 800 g/L, in each case relative to the total composition.

6. The composition according to claim 3, wherein, the at least one thermally expandable compound is a graphite intercalation compound.

7. The composition according to claim 6, wherein, the graphite intercalation compound has a particle size of at least 80%>75 m and is present in a proportion of approximately 0.3 to approximately 6.0 wt %, relative to the total composition.

8. The composition according to claim 1, wherein the at least one hydraulic binder is a pH-neutral or alkaline binder.

9. The composition according to claim 8, wherein the hydraulic binder is at least one member selected from the group consisting of cement, trass, pozzolan, hydraulic lime, and gypsum.

10. The composition according to claim 1, wherein the blowing-agent mixture comprises compounds that, after being mixed, react with one another with formation of at least one of carbon dioxide, hydrogen, oxygen, and nitrogen.

11. The composition according to claim 1, wherein the blowing-agent mixture comprises an oxygen carrier and a catalyst.

12. The composition according to claim 1, wherein the composition further comprises at least one member selected from the group consisting of fiber, a woven fabric of fiber, and a nonwoven fabric of fiber, and wherein the fiber is at least one member selected from the group consisting of glass, cellulose, polyethylene, polypropylene, polyester, polyamide fiber, carbon fiber, rock wool, and mineral wool.

13. The composition according to claim 1, wherein the composition further comprises a setting retarder or a setting accelerator.

14. The composition according to claim 1, wherein the foam stabilizer is at least one member selected from the group consisting of hydrophobed calcium carbonate, hydrophobed titanium dioxide, hydrophobed barium sulfate, hydrophobed aluminum, a surfactant, bentonite, starch, a starch derivative, a gelatin, cellulose, a cellulose derivative, a polymer, and a polymer dispersion.

15. An inorganic fire-protection foam, which is produced by a process that comprises reacting the hydraulically binding composition according to claim 1, and water or an aqueous solution.

16. The fire-protection foam according to claim 15, wherein the foam in a set dry state has a density of <800 g/L.

17. A fire-protection device, comprising: a fire-protection foam according to claim 15.

18. The fire-protection device according to claim 17, wherein the fire-protection foam is configured as a molded block or as a filling in a door, a door frame, a hollow profile, a partition wall or a ceiling panel.

19. A method for producing a fire-protection device, the method comprising: mixing the composition according to claim 1 with water or aqueous solution to obtain a mixture, and then filling the mixture into a hollow body comprising one or more cavities, wherein the composition cures while forming a fire-protection foam.

20. A method of foaming a space to impart fire protection to the space, the method comprising: applying the inorganic fire-protection foam according to claim 15 to the space, wherein the space is selected from the group consisting of an opening, a cable, a pipe penetration in a wall, a floor, a ceiling, a joint between a ceiling and a wall part, an opening between a masonry part and a construction part, an opening between a ceiling and a wall, and an opening between an outside wall and a curtain-wall facade of a building.

21. A method of producing a fire-protection device or a firestop, the method comprising: incorporating the inorganic fire-protection foam according to claim 15 into a fire-protection device or into a firestop.

22. The composition according to claim 1, wherein said composition excludes mica.

Description

EXEMPLARY EMBODIMENTS

(1) The individual components listed in the examples and comparison examples are respectively mixed and homogenized. For use, these mixtures are mechanically mixed with one another in a container until homogeneous intermixing has been achieved and until foaming has begun.

(2) Gas-Burner Test

(3) To appraise the behavior of the foamed inventive composition in the fire situation, a firewall was respectively created. For this purpose, a penetration with a diameter of 82 mm was created by means of a core drill in an aerated concrete block with a depth of 100 mm. By means of the compositions described in the comparison examples and examples, a cable (EN 1366-3; B-cable/NYY 195 RM-J; outside diameter 19 mm; PVC sheath; length 170 mm) was installed centrally in the penetration over the entire depth of the aerated concrete block, such that the space between the cable and the wall of the aerated concrete block was filled with foam. After the composition had cured, the firewall was flamed for 30 minutes from a distance of 25 cm with a supplied-air gas burner (natural gas/air, rating approximately 8 kW; Thuringer Model ESL100 benchtop burner, Herbert Arnold Co.). The condition of the composition, especially the foam structure, was appraised by visual inspection, and the interfaces to the cable as well as to the inside wall of the penetration were examined for ring formation.

COMPARISON EXAMPLE 1

-Gypsum without Expandable Compound

(4) TABLE-US-00001 Ingredient Content [wt %] Calcium sulfate (hemihydrate).sup.a) 58.8 Manganese dioxide.sup.b) 0.3 Calcium carbonate, coated.sup.c) 3.2 Glass fibers.sup.d) 1.2 Gypsum (dihydrate).sup.e) 0.5 3% hydrogen peroxide solution 36.0 .sup.a)Building and electrical plaster (-gypsum), Baumit GmbH .sup.b)Manganese gray, Kremer Pigmente GmbH & Co. KG .sup.c)Omyabond 520-OM; Omya GmbH .sup.d)Short-cut glass fibers, FGCS 70-30/3, STW Co. .sup.e)Lenzin (calcium sulfate dihydrate), Kremer Pigmente GmbH & Co. KG

COMPARISON EXAMPLE 2

-Gypsum without Expandable Compound

(5) TABLE-US-00002 Ingredient Content [wt %] Calcium sulfate (hemihydrate).sup.a) 60.5 Manganese dioxide.sup.b) 0.4 Calcium carbonate, coated.sup.c) 3.8 Natural gypsum.sup.d) 2.0 Plastic fibers.sup.e) 1.3 3% hydrogen peroxide solution 32.0 .sup.a)Siladent high-strength formulated plaster HF1 (-gypsum), Siladent Dr. Bhme & Schps GmbH .sup.b)Manganese gray, Kremer Pigmente GmbH & Co. KG .sup.c)Omyabond 520-OM, Omya GmbH .sup.d)Lenzin (calcium sulfate dihydrate), Kremer Pigmente GmbH & Co. KG .sup.e)Polyester fiber filler 231/100; STW Co.

COMPARISON EXAMPLE 3

-Gypsum with Expandable Graphite; Too High Foam Density

(6) TABLE-US-00003 Ingredient Content [wt %] Calcium sulfate (hemihydrate).sup.a) 65.5 Manganese dioxide.sup.b) 0.3 Calcium carbonate, coated.sup.c) 3.6 Natural gypsum.sup.d) 1.5 Pentaerythritol.sup.e) 2.3 Expandable graphite.sup.f) 1.9 Plastic fibers.sup.g) 2.7 3% hydrogen peroxide solution 22.2 .sup.a)Siladent high-strength formulated plaster HF1 (alpha gypsum), Siladent Dr. Bhme & Schps GmbH .sup.b)Manganese gray, Kremer Pigmente GmbH & Co. KG .sup.c)Omyabond 520-OM, Omya GmbH .sup.d)Lenzin (calcium sulfate dihydrate), Kremer Pigmente GmbH & Co. KG .sup.e)Charmor PM 40, of Perstorp .sup.f)Nord-Min 351, of Nordmin Engineering Ltd .sup.g)Short-cut polyester cord filaments 164 S/4 mm, STW Co.

COMPARISON EXAMPLE 4

-Gypsum with too High Proportion of Expandable Graphite

(7) TABLE-US-00004 Ingredient Content [wt %] Calcium sulfate (hemihydrate).sup.a) 55.4 Manganese dioxide.sup.b) 0.5 Calcium carbonate, coated.sup.c) 3.0 Natural gypsum.sup.d) 1.8 Pentaerythritol.sup.e) 1.9 Expandable graphite.sup.f) 7.0 Glass fibers.sup.g) 1.9 3% hydrogen peroxide solution 28.5 .sup.a)Siladent high-strength formulated plaster HF1 (alpha gypsum), Siladent Dr. Bhme & Schps GmbH .sup.b)Manganese black, Kremer Pigmente GmbH & Co. KG .sup.c)Omyabond 520-OM, Omya GmbH .sup.d)Lenzin (calcium sulfate dihydrate), Kremer Pigmente GmbH & Co. KG .sup.e)Charmor PM 40, Perstorp .sup.f)Nord-Min 351, of Nordmin Engineering Ltd .sup.g)Short-cut glass fibers, FGCS 70-30/3, STW Co.

COMPARISON EXAMPLE 5

-Gypsum with Very Fine Expandable Graphite Particles

(8) TABLE-US-00005 Ingredient Content [wt %] Calcium sulfate (hemihydrate).sup.a) 59.0 Manganese dioxide.sup.b) 0.5 Calcium carbonate, coated.sup.c) 3.2 Natural gypsum.sup.d) 2.4 Pentaerythritol.sup.e) 1.9 Expandable graphite.sup.f) 2.0 Glass fibers.sup.g) 2.0 3% hydrogen peroxide solution 29.0 .sup.a)Siladent high-strength formulated plaster HF1 (alpha gypsum), Siladent Dr. Bhme & Schps GmbH .sup.b)Manganese black, Kremer Pigmente GmbH & Co. KG .sup.c)Omyabond 520-OM, Omya GmbH .sup.d)Lenzin (calcium sulfate dihydrate), of Kremer Pigmente GmbH & Co. KG .sup.e)Charmor PM 40, Perstorp .sup.f)Nord-Min 20 (at least 80% below 75 m), of Nordmin Engineering Ltd .sup.g)Short-cut glass fibers, FGCS 70-30/3, STW Co.

EXAMPLE 1

-Gypsum with Expandable Graphite

(9) TABLE-US-00006 Ingredient Content [wt %] Calcium sulfate (hemihydrate).sup.a) 59.0 Manganese dioxide.sup.b) 0.4 Calcium carbonate, coated.sup.c) 3.2 Natural gypsum.sup.d) 1.3 Pentaerythritol.sup.e) 2.0 Expandable graphite.sup.f) 1.7 Plastic fibers.sup.g) 2.4 3% hydrogen peroxide solution 30.0 .sup.a)Siladent high-strength formulated plaster HF1 (-gypsum), Siladent Dr. Bhme & Schps GmbH .sup.b)Manganese gray, Kremer Pigmente GmbH & Co. KG .sup.c)Omyabond 520-OM, Omya GmbH .sup.d)Lenzin (calcium sulfate dihydrate), Kremer Pigmente GmbH & Co. KG .sup.e)Charmor PM 40, Perstorp .sup.f)Nord-Min 351, of Nordmin Engineering Ltd .sup.g)Short-cut polyester cord filaments 164 S/1 mm, STW Co.

EXAMPLE 2

-Gypsum with Expandable Vermiculite

(10) TABLE-US-00007 Ingredient Content [wt %] Calcium sulfate (hemihydrate).sup.a) 52.1 Manganese dioxide.sup.b) 0.4 Calcium carbonate, coated.sup.c) 2.9 Natural gypsum.sup.d) 2.1 Pentaerythritol.sup.e) 1.6 Vermiculite (fine).sup.f) 10.0 Glass fibers.sup.g) 1.9 3% hydrogen peroxide solution 29.0 .sup.a)Casea Spezial 40 (-gypsum), Siladent Dr. Bhme & Schps GmbH .sup.b)Manganese gray, Kremer Pigmente GmbH & Co. KG .sup.c)Omyabond 520-OM, Omya GmbH .sup.d)Lenzin (calcium sulfate dihydrate), Kremer Pigmente GmbH & Co. KG .sup.e)Charmor PM 40, Perstorp .sup.f)Vermiculite ADT-V052; ADT Co. .sup.g)Short-cut glass fibers, FGCS 70-30/3, STW Co.

EXAMPLE 3

-Gypsum with Cement Content and Expandable Graphite

(11) TABLE-US-00008 Ingredient Content [wt %] Calcium sulfate (hemihydrate).sup.a) 51.5 Manganese dioxide.sup.b) 0.5 Calcium carbonate, coated.sup.c) 2.8 Natural gypsum.sup.d) 2.0 Pentaerythritol.sup.e) 1.6 Expandable graphite.sup.f) 1.3 Glass fibers.sup.g) 1.3 Cement.sup.h) 10.0 3% hydrogen peroxide solution 29.0 .sup.a)Siladent high-strength formulated plaster HF1 (-gypsum), Siladent Dr. Bhme & Schps GmbH .sup.b)Manganese gray, Kremer Pigmente GmbH & Co. KG .sup.c)Omyabond 520-OM, Omya GmbH .sup.d)Lenzin (calcium sulfate dihydrate), Kremer Pigmente GmbH & Co. KG .sup.e)Charmor PM 40, Perstorp .sup.f)Nord-Min 20 (at least 80% below 75 m), Nordmin Engineering Ltd .sup.g)Short-cut glass fibers, FGCS 70-30/3, STW Co. .sup.h)Secar 51, Kerneos Co.

(12) TABLE-US-00009 TABLE 1 Properties of the exemplary formulations (foam density, setting time, observations in the gas-burner test) Foam density Setting time Example [g/L] [min] Observation in the gas-burner test Comparison 1 220 ~15 Cracking and fissuring Comparison 2 210 ~10 Slight cracking Comparison 3 400 ~10 Degradation and destruction of the foam Comparison 4 240 ~9 Degradation and destruction of the foam Comparison 5 235 ~9 Slight cracking and partial degradation of the foam 1 230 ~11 No cracking and no degradation of the foam 2 300 ~11 No cracking and no degradation of the foam 3 260 ~25 No cracking and no degradation of the foam