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CA-3099650-C - A THERMAL AND/OR FIRE RESISTANT PANEL, A MOUNTING ASSEMBLY, AND A KIT

CA3099650CCA 3099650 CCA3099650 CCA 3099650CCA-3099650-C

Abstract

Disclosed herein is a thermal and/or fire resistant panel comprising: a panel body comprising a fire resistant composition, wherein the fire resistant composition comprises: a silane cross-linked hybrid inorganic polymer; and a siloxane.

Inventors

  • ROBERTO JAVIER HERBON
  • Lukas KRELLMANN
  • Carmelo Dell'Olio

Assignees

  • CBG SYSTEMS INTERNATIONAL PTY LTD

Dates

Publication Date
20260505
Application Date
20190517
Priority Date
20180519

Claims (3)

  1. CLAIMS 1. A thermal and/or fire resistant panel comprising: a panel body comprising a fire resistant composition, wherein the fire resistant composition comprises: a silane cross-linked hybrid inorganic polymer; and a siloxane, wherein the silane cross linked hybrid inorganic polymer is of Formula I: Rm[M2O]x[Al2O3]y[SiO2]zXq.PH2O Formula I wherein: R represents an organic functional group; M is an alkali metal; X is selected from chlorine and fluorine; m is >0; q is ≧0; x is from 1 to 1.6; y is from 1.0 to 1.6; x/y is from 1.0 to 1.6; z is from 3 to 65; z/y is >1.0; and P is from 3 to 5.
  2. 2. The thermal and/or fire resistant panel of claim 1, wherein the thermal and/or fire resistant panel comprises less than 20 wt% organic matter. 3. The thermal and/or fire resistant panel of claim 1 or claim 2, wherein the organic functional group R is a silane of the form R1nSiO4-n, wherein R1 represents an organic moiety and n is selected from 1, 2, and 3. CA 3099650 46 4. The thermal and/or fire resistant panel of any one of claims 1 to 3, wherein the silane cross-linked hybrid inorganic polymer comprises a glycidyl silane. 5. The thermal and/or fire resistant panel of any one of claims 1 to 4, wherein the panel is a panel of a refractory material. 6. The thermal and/or fire resistant panel of any one of claims 1 to 5, wherein wood is absent from the panel. 7. The thermal and/or fire resistant panel of any one of claims 1 to 6, wherein the panel body is laminated with a layer of a woven material comprising the fire resistant composition. 8. The thermal and/or fire resistant panel of claim 7, wherein the layer of the woven material is selected from the group consisting of: glass fibre, carbon cloth, basalt cloth and steel mesh. 9. The thermal and/or fire resistant panel of any one of claims 1 to 8, wherein the panel is a marine panel. 10. The thermal and/or fire resistant panel of any one of claims 1 to 9, wherein the dimensions of the thermal and/or fire resistant panel are stable under the effects of heat in the range of 0 to 1100 °C, wherein the panel is stable when one or more of the following apply a) the dimensions of the panel are stable; b) no cracks or apertures occur in the panel; and c) when the heat exposure is on one side of the panel one or more of the following apply: (i) flaming on the unexposed side of the panel does not occur; (ii) ignition of a cotton wool pad on the unexposed side of the panel does not occur over cracks and openings that lead to the passage of hot gases from the heat exposed side of the panel; CA 3099650 47 (iii) a 6 mm-diameter gap gauge cannot be passed through the panel such that the gauge projects from the heat exposed side and can be moved a distance of 150 mm along the gap; and (iv) a 25 mm-diameter gap gauge cannot be passed through the panel such that the gauge projects from the heat exposed side. 11. The thermal and/or fire resistant panel of any one of claims 1 to 10, wherein fire resistant panel has dimensions of up to 1200 mm x up to 2400 mm x up to 25 mm. 12. The thermal and/or fire resistant panel of any one of claims 1 to 11, wherein at least one surface of the panel is lined, treated, coated or impregnated with the fire resistant composition. 13. The thermal and/or fire resistant panel of any one of claims 1 to 12, wherein the panel body is a laminate and the laminate shows no sign of laminate destruction after 42 days immersion in 3.5% salt solution. 14. The thermal and/or fire resistant panel of any one of claims 1 to 13, wherein the siloxane is one or more of liquid oligomeric siloxane, silanol terminated polydimethyl siloxane, isobutyltriethoxysilane, and tripotassium propylsilane triolate. 15. The thermal and/or fire resistant panel of any one of claims 1 to 14, wherein the panel body is a thermal insulating blank. 16. The thermal and/or fire resistant panel of claim 15, wherein the thermal insulating blank comprises: - one or more of refractories, fibres, and amorphous alkaline earth silicates, - colloidal silica; and - starch. 17. The thermal and/or fire resistant panel of claims 15 or claim 16, wherein the thermal insulating blank is a compressed fibre board of refractory fibres. 18. The thermal and/or fire resistant panel of claims 15, wherein the thermal insulating blank comprises one or more of polycrystalline wool, amorphous silica, water, and polyacrylamide. CA 3099650 48 19. The thermal and/or fire resistant panel of any one of claims 15 to 18, wherein the thermal insulating blank has a thermal conductivity value of less than 0.
  3. 3 W/m.K at temperatures at 1000°C or less. 20. The thermal and/or fire resistant panel of any one of claims 1 to 19, wherein the panel further comprises a vapour barrier layer on at least one or more faces of the panel body. 21. A method of preparing a fire resistant panel comprising: applying a resin of a thermal resistant composition to a surface of a panel body; and curing the resin to form a fire resistant panel including a fire resistant composition comprising: a silane cross-linked hybrid inorganic polymer; and a siloxane, wherein the silane cross linked hybrid inorganic polymer is of Formula I: Rm[M2O]x[Al2O3]y[SiO2]zXq.PH2O Formula I wherein: R represents an organic functional group; M is an alkali metal; X is selected from chlorine and fluorine; m is >0; q is ≧0; x is from 1 to 1.6; y is from 1.0 to 1.6; x/y is from 1.0 to 1.6; z is from 3 to 65; CA 3099650 49 z/y is >1.0; and P is from 3 to 5. 22. The method of claim 21, wherein the resin comprises: a hybrid inorganic polymer; a silane cross-linking agent; the siloxane. 23. The method of claim 22, wherein the resin further comprises an alkali metal silicate. 24. The method of any one of claims 21 to 23, wherein the organic functional group R is a silane of the form R1nSiO4-n, wherein R1 represents an organic moiety and n is selected from 1, 2, and 3. 25. The method of any one of claim 21 to 24, wherein the panel is a panel of a refractory material. 26. The method of any one of claims 21 to 25, wherein the Al in the composition is sourced from metakaolin and the alkali metal in the composition is sourced from alkali metal silicate. 27. The method of any one of claims 21 to 26, wherein the resin, prior to curing, comprises 4:13 to 3:5 w/w metakaolin to alkali metal silicate. 28. The method of any one of claims 21 to 27, wherein the resin, prior to curing, comprises 20 wt% to 30 wt% metakaolin. 29. The method of any one of claims 21 to 28, wherein the resin, prior to curing, comprises 50 wt% to 65 wt% alkali metal silicate. 30. The method of any one of claims 21 to 29, wherein the resin, prior to curing, comprises 1 wt% to 10 wt% silane cross-linking agent. CA 3099650 50 31. The method of claims 22 or 30, wherein the silane cross-linking agent comprises an amino silane or a glycidyl silane. 32. The method of claim 31, wherein the silane cross-linking agent comprises a glycidyl silane. 33. The method of any one of claims 21 to 32, wherein the resin is prepared from 0.5 wt% to 5 wt% siloxane. 34. The method of any one of claims 21 to 33, wherein the siloxane is one or more of liquid oligomeric siloxane, silanol terminated polydimethyl siloxane, isobutyltriethoxysilane, and tripotassium propylsilane triolate. 35. The method of any one of claims 21 to 34, wherein the resin further comprises epoxy. 36. The method of claim 35, wherein the resin comprises between 6% to 10% w/w epoxy. 37. The method of any one of claims 21 to 36, wherein the panel body is laminated with a layer of a woven material comprising the fire resistant composition. 38. The method of claim 37, wherein the layer of the woven material is selected from the group consisting of: glass fibre, carbon cloth, basalt cloth and steel mesh. 39. The method of any one of claims 21 to 38, wherein the panel is a marine panel. 40. The method of any one of claims 21 to 39, wherein wood is absent from the panel. 41. The method of any one of claims 21 to 40, wherein the panel body is a thermal insulating blank. CA 3099650 51 42. The method of claim 41, wherein the thermal insulating blank is a compressed fibre board of refractory fibres. 43. Use of a resin comprising: a hybrid inorganic polymer; a silane cross-linking agent; and a siloxane; in the preparation of a fire resistant composition in a fire resistant panel according to any one of claims 1 to 19. 44. A kit for installing a thermal and/or fire insulation panel assembly on a wall or mounting surface, the kit comprising: one or more thermal and/or fire resistant panels according to any one of claims 1 to 19; a locating frame for receiving the thermal and/or fire resistant panels; and one or more thermal and/or fire insulation panel retainers configured to fasten to or otherwise mount onto the locating frame. 45. A thermal and/or fire resistant panel assembly comprising; one or more thermal and/or fire resistant panels according to any one of claims 1 to 19; a locating frame configured to be mounted on a wall or other surface, the locating frame receiving at least portions of the one or more thermal and/or fire insulation panels thereon; and one or more panel retainers fastened to or otherwise mounted on the locating frame.

Description

A thermal and/or fire resistant panel, a mounting assembly, and a kit Field of the invention The present technology relates generally to thermal and/or fire insulation material, thermal and/or fire resistant panels, insulation assemblies and kits for their 5 assembly. Embodiments of the technology find particularly effective application in inhibiting heat and/or fire transfer in marine applications such as in seagoing ships and fast ferries but the technology is generally suitable for any building or land going or flying vehicle, wherein thermal and/or fire resistant panels, systems and assemblies are installed to inhibit heat transfer and/or fire transfer from one side of a partition, wall, 10 deck or floor, to the other. Background of the invention Fires can be devastating in seagoing vessels or other vehicles, where, for one reason or another, people onboard cannot quickly or easily move to safety via egress or movement to some other area of the vehicle or vessel. Oftentimes in emergency 15 situations there are multiple problems that simultaneously become of relevance, such as engine fire, galley fire, hull breach and structure buckling which inhibits operation of lifeboat davits and free passenger movement around the vessel through bulkheads and other areas. It is therefore important to delay, for as long as possible, the transfer of heat from one or more rooms in which a fire may have broken out, to other areas of the 20 vehicle or vessel. It is also useful for a seagoing vessel or other land-going or flying vehicle to have a light structure, so as to transport its cargo or passengers as efficiently as possible, and to keep it afloat for as long as possible in an emergency situation. Known thermal and fire insulation materials come with a heavy weight penalty, in 25 particular since they are installed with a high wrap factor. They are formed around the contours of the seagoing vessel or vehicle, including around strengthening and stiffening beams and channels. There are several guidelines and standards with which designers of at least some parts of some types of seagoing vessels are required to at least consider or 1 comply, including A60-class structural fire protection system; B15 Partitions and ceilings; H60-class structural fire protection systems; H 120 Structural fire protection systems; N30 structural fire protection systems; SOLAS (Safety of Life at Sea); HSC Code (High Speed Craft); ISO fire standards; buildings fire standards; aviation fire 5 standards; and FTP (Fire Test Procedure Code). As an example of a relevant consideration in at least one guideline or standard, the presence of high levels of organic compounds is undesirable or banned. In some other guidelines or standards it is prescribed that on one side of a barrier, when there has been present for one hour a heat of about 945 Celsius, the temperature reading averaged over five evenly-spaced 10 thermocouples mounted on the other side should be less than 140 Celsius. The present invention seeks to provide a new insulation material and/or thermal and/or fire resistant panel assembly and/or kit which seeks to ameliorate one or more of the above disadvantages or at least make a new alternative. Summary of the invention In a first aspect of the invention, there is provided a thermal and/or fire resistant panel comprising: a panel body comprising a fire resistant composition, wherein the fire resistant composition comprises: a silane cross-linked hybrid inorganic polymer; and a siloxane. In an embodiment, the panel body has at least one surface lined, treated, coated, or impregnated with the fire resistant composition. In an embodiment, the silane cross linked hybrid inorganic polymer is of Formula I: Formula I 2 wherein R represents an organic functional group; M is an alkali metal; X is selected from chlorine and fluorine; m is >0; q is ~0; xis from 1 to 1.6; y is from 1.0; x/y is from 1.0 to 1.6; z is from 3 to 65; z/y is ~1.0; and Pis from 3 to 5. In one form of the above embodiment, M is an alkali metal selected from the 5 group consisting of Na, K, Li, or mixtures thereof. In one form of the above embodiment, the organic functional group R is a silane of the form R1nSiO4-n, wherein R1 represents an organic moiety and n is selected from 1, 2, or 3. Preferably, the silane is a glycidyl silane or an amino silane. More preferably, the silane is a glycidyl silane. In an embodiment, a ratio of Al to alkali metal in the fire resistant composition is from about 4: 13 to about 3:5 when measured as metakaolin and alkali metal silicate respectively. In an embodiment, the composition comprises from about 20 wt% to about 30 wt% Al when measured as metakaolin. In an embodiment, the composition comprises from about 50 wt% to about 65 wt% alkali metal when measured as alkali metal silicate. In an embodiment, the composition comprises from about 1 wt% up to about 10 wt% silane cross-linking agent. Preferably, the composition comprises from about 2 wt