Inorganic fire protection and insulation foam and use thereof

Patent metadata

Field	Value
Publication number	US-10730796-B2
Application number	US-201615775806-A
Country	US
Kind code	B2
Filing date	Dec 1, 2016
Priority date	Dec 3, 2015
Publication date	Aug 4, 2020
Grant date	Aug 4, 2020

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.

First claim

The invention claimed is:

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 μm 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.

Assignees

• Hilti Ag

Inventors

• Kluj Esther Rahel
• Simon Sebastian
• Paetow Mario
• Miller Jekaterina

Classifications

• C04B28/145 Primary

  Calcium sulfate hemi-hydrate with a specific crystal form · CPC title

• C04B2111/00663

  as filling material for cavities or the like · CPC title

• C04B2111/28

  Fire resistance, i.e. materials resistant to accidental fires or high temperatures · CPC title

• C04B2111/285

  Intumescent materials · CPC title

• C04B38/02

  by adding chemical blowing agents · CPC title