Composite panel with fire resistant face sheets
View Patent ↗A fire resistant laminate for application to a core structure ( 12 ) to form a sandwich panel ( 10 ) having fire resistant face sheets ( 14 & 16 ). The laminate includes a fire protection ( 18 ) in which at least one layer of fibers ( 22 ) is embedded within a cured inorganic polymer matrix ( 24 ). The laminate further includes an adhesive layer ( 20 ) for bonding to the core structure.
1. A fire resistant laminate comprising:
(A) a fire protection layer comprising an inner surface and an outer surface, said fire protection layer comprising fibers and a cured inorganic polymer; and
(B) an adhesive layer comprising an uncured phenolic adhesive which has been applied to said inner surface of said fire protection layer.
2. A Fire resistant laminate according to claim 1 wherein at least a portion of said fibers are located at said inner surface to provide an inner surface which is textured by said fibers.
3. A fire resistant laminate according to claim 2 wherein said inner surface of said fire protection layer comprises exposed fibers which consist essentially of fibers that are not coated with said cured inorganic polymer.
4. A fire resistant laminate according to claim 1 wherein said cured inorganic polymer is an alkali aluminosilicate geopolymer.
5. A fire resistant laminate according to claim 1 wherein said cured alkali aluminosilicate geopolymeric matrix comprises a composition after dehydration having the formula:
yM 2 O:Al 2 O 2 :xSIO 2
where x is a value lying between 6.5 and 70, y is a value lying between 0.95 and 9.50 and M is either Na, K or a mixture of Na and K.
6. A fire resistant laminate according to claim 1 wherein said fibers are selected from the group consisting of graphite fibers, ceramic fibers and glass fibers.
7. A fire resistant laminate according to claim 1 wherein said fibers comprise at least two layers of fibers.
8. A method for making a fire resistant laminate comprising the steps of:
(A) providing a fire protection layer comprising an inner surface and an outer surface, said fire protection layer comprising fibers and a cured inorganic polymer; and
(B) applying an uncured phenolic adhesive layer to said inner surface of said fire protection layer.
9. A method for making a fire resistant laminate according to claim 8 wherein at least a portion of said fibers are located at said inner surface to provide an inner surface which is textured by said fibers.
10. A method for making a fire resistant laminate according to claim 9 wherein said inner surface of said fire protection layer comprises exposed fibers which consist essentially of fibers that are not coated with said cured inorganic polymer.
11. A method for making a fire resistant laminate according to claim 8 wherein said cured inorganic polymer is an alkali aluminosilicate geopolymer.
12. A method for preparing a fire resistant laminate according to claim 11 wherein said cured alkali aluminosilicate geopolymeric matrix comprises a composition after dehydration having the formula:
yM 2 O:Al 2 O 2 :xSIO 2
where x is a value lying between 6.5 and 70, y is a value lying between 0.95 and 9.50 and M is either Na, K or a mixture of Na and K.
13. A method for making a fire resistant laminate according to claim 8 wherein said fibers are selected from the group consisting of graphite fibers, ceramic fibers and glass fibers.