FI3555190T3 - Fire-resistant and alkali-resistant surfacing product for foam boards - Google Patents

Fire-resistant and alkali-resistant surfacing product for foam boards Download PDF

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Publication number
FI3555190T3
FI3555190T3 FIEP17825571.7T FI17825571T FI3555190T3 FI 3555190 T3 FI3555190 T3 FI 3555190T3 FI 17825571 T FI17825571 T FI 17825571T FI 3555190 T3 FI3555190 T3 FI 3555190T3
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Finland
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weight
product according
coating
coating product
elastomer
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FIEP17825571.7T
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Finnish (fi)
Inventor
Christelle Silioc
Samuel Solarski
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Saint Gobain Adfors
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C08J5/241—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres
    • C08J5/244—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres using glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/0405—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres
    • C08J5/043—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres with glass fibres
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C08J5/249—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs characterised by the additives used in the prepolymer mixture
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/36—Sulfur-, selenium-, or tellurium-containing compounds
    • C08K5/43—Compounds containing sulfur bound to nitrogen
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D109/00—Coating compositions based on homopolymers or copolymers of conjugated diene hydrocarbons
    • C09D109/06—Copolymers with styrene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/048—Natural or synthetic rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/104—Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0285—Condensation resins of aldehydes, e.g. with phenols, ureas, melamines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/72—Density
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/73—Hydrophobic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2309/00—Characterised by the use of homopolymers or copolymers of conjugated diene hydrocarbons
    • C08J2309/06—Copolymers with styrene

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  • Organic Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Inorganic Chemistry (AREA)
  • Wood Science & Technology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Textile Engineering (AREA)
  • Building Environments (AREA)
  • Laminated Bodies (AREA)
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Description

1 EP3 555 190
FIRE-RESISTANT AND ALKALI-RESISTANT SURFACING PRODUCT FOR
FOAM BOARDS
The present invention relates to a facing product for organic foam boards intended to be integrated into external thermal insulation composite systems (ETICS). It also relates to organic foam boards bearing such a facing product on at least one of their two main faces, preferably on their two main faces. Finally, the invention relates to an external thermal insulation composite system containing an organic foam board with a facing product according to the invention.
External thermal insulation composite systems generally comprise a board of a thermally insulating material, typically a rigid organic foam board, placed against the external face of a building facade, generally by means of an adhesive mortar.
The board of insulating material advantageously comprises, on its two faces, a facing material intended to facilitate its production and to improve its usage properties, such as the mechanical strength.
The material of choice for these facing products is a nonwoven glass textile, typically a glass mat, or glass veil.
The glass typically used for the glass veils intended for the facing of foam boards is E glass which is quite sensitive to basic or alkaline substances. This sensitivity of the E glass to alkaline materials poses a problem in an ETICS since the two faces of the insulating board come into contact with an alkaline material: the adhesive mortar on the face turned toward the facade, on the one hand, and the finishing mortar on the face turned toward the outside, on the other hand.
In order to reduce the alkali sensitivity and prevent the degradation of the mechanical properties of the facing products and of the thermal insulation products (in board form) containing them, it would of course be possible to coat them with a protective organic layer, but such a layer would undesirably reduce the fire resistance of the boards.
The objective of the present invention is to provide a facing product for foam boards which has both a good fire resistance and good mechanical properties and which furthermore retains these good mechanical properties after a water aging test and after an alkali aging test.
2 EP3 555 190
Another objective of the present invention is to increase the hydrophobic nature of the facing products and of the thermal insulation products containing them, without significantly reducing the fire resistance of the products.
These objectives have been achieved by means of the development of a particular binder for binding the fibers of the facing glass veil, and in particular by means of the selection of a particular mineral flame retardant and of a restricted range of the amount of this flame retardant.
One subject of the present invention is therefore a facing product for foam boards, comprising a glass veil bonded by an elastomer binder, characterized in that the elastomer binder contains: (a) an organic elastomer and (b) from 8 to 18 % by weight of ammonium sulfamate relative to the sum of organic elastomer and ammonium sulfamate.
The glass veil used in the present invention is a nonwoven textile, manufactured by a wetlaid process or by a drylaid process, for example by a drylaid carded process or by an airlaid process.
The surface density of the unbonded glass veil is advantageously between 30 and 350 g/m?, preferably between 40 and 250 g/m?, more preferentially between 50 and 100 g/m? and ideally between 55 and 80 g/m?.
After formation, the crude or “bare” veil is impregnated with an aqueous binder composition formed by mixing a latex of the organic elastomer and an aqueous solution of ammonium sulfamate. The aqueous binder composition may be applied to the veil by any technique that makes it possible to control the final amount of binder after drying and crosslinking. As examples, mention may be made of spraying the composition on the veil, immersing the veil in the binder composition, curtain coating or roll coating.
The aqueous binder composition preferably has a solids content of between 30 and 70 % by weight, preferably between 40 and 60 % by weight, in particular between 45 and 55 % by weight.
3 EP3 555 190
Ammonium sulfamate (H2N-S(=O)20* NH4*; CAS number 7773-06-0) is preferably present in the agueous binder composition in the dissolved state in the agueous phase.
The organic elastomer which constitutes the matrix of the elastomer binder is a —self-crosslinking elastomer, a styrene-butadiene-methacrylate copolymer bearing anionic carboxylate functions. These carboxylate functions participate not only in the crosslinking reaction, but they give the latex an overall negative charge which improves the adhesion of the latex to the glass fibers. By “self-crosslinking”, is designated any elastomer as described that does not require the addition of a vulcanization or crosslinking agent. Mention may be made, as examples of latices that can be used as organic elastomers in the binder of the present invention, of the products of the Litex® S range from Synthomer, for example the Litex® S 10656, Litex® S 9074 and Litex® S 9076 latices; or else the Rovene 4019 and
Rovene 4176 products from Mallard Creek Polymers.
The aqueous binder composition is therefore preferably a self-crosslinking anionic > SBR latex containing ammonium sulfamate in dissolved form.
This agueous binder composition is applied to the bare unbonded veil in an amount such that, after drying and crosslinking of the binder, the amount of elastomer binder, relative to the weight of the unbonded glass veil, is advantageously between 15 and 40 % by weight, preferably between 20 and 30 % 20 by weight, more particularly between 22 and 28 % by weight.
The ammonium sulfamate content of the elastomer binder is between 8 and 18 % by weight, preferably between 9 and 17 % by weight, and ideally between 10 and % by weight, relative to the sum of organic elastomer and ammonium sulfamate. The organic elastomer consequently represents from 92 to 82 % by > weight, preferably from 83 to 91 % by weight, and ideally from 85 to 90 % by weight, relative to the sum of organic elastomer and ammonium sulfamate.
When the binder contains less than 8 % by weight of ammonium sulfamate and, surprisingly, more than 18 % by weight of ammonium sulfamate, the facing product does not pass the fire resistance test (see the examples and comparative examples).
4 EP3 555 190
The elastomer binder used in the present invention preferably consists solely of ammonium sulfamate and organic elastomer, i.e. it is preferably free of other additives. When additives are present, for example dyes or fillers, they represent no more than 10 % by weight, preferably no more than 5 % by weight of the elastomer binder.
In order to render the facing product of the present invention yet more alkali resistant, the applicant proposes to cover one face of the facing product with a hydrophobic coating. This coated face will be the one which will not come into contact with the foam but will be turned toward the outside and will be in contact with the adhesive mortar or the finishing mortar when the foam board is integrated into an ETICS.
However, coating the facing product with a hydrophobic organic polymer poses two problems: - it reduces the fire resistance of the facing product and of the thermal insulation product (in board form) containing it, - it increases the higher heating value (HHV) of the facing product and of the thermal insulation product containing it, and - it reduces the adhesion of adhesive and/or finishing mortars to the thermal insulation product containing it.
The applicant has developed a hydrophobic coating which not only protects the facing product even more effectively against the alkalinity of the mortars of the
ETICS, but which does not increase the higher heating value (HHV) nor degrade the fire resistance or the adhesion of the adhesive and/or finishing mortars.
This additional hydrophobic coating is applied to a single face of the facing product of the present invention and differs by the fact that it comprises a large proportion of mineral particles, more specifically from 75 to 90 % by weight of mineral particles, and only from 10 to 25 % by weight of a crosslinked organic polymer.
A hydrophobic coating is understood to mean a coating that has a water absorption after two hours, measured by the Cobb test (ISO 535), of less than 0.1 g.
EP3 555 190
The hydrophobic nature of the additional coating is mainly due to the hydrophobic nature of the mineral particles that are advantageously mineral particles that have undergone a hydrophobizing treatment, for example a grafting of alkyl-type fatty chains or of polydimethylsiloxane-type chains. 5 The applicant has successfully used calcium carbonate particles rendered hydrophobic by grafting of alkyl chains, available under the trade name Mikhart C,
AC, MUOST, MU12T and MU17T from the company Provencale (Brignoles, France).
The crosslinked organic polymer used to bind the mineral particles together and to the nonwoven glass veil of the present invention is advantageously identical or very similar to the organic elastomer used for binding the glass veil. This identicalness or similarity guarantees a good compatibility and favors a good adhesion of the hydrophobic coating to the nonwoven glass veil according to the present invention.
The organic polymer used to form the additional hydrophobic coating is therefore advantageously a self-crosslinking styrene-butadiene rubber (SBR), optionally containing one or more other comonomers, for example a methacrylate comonomer, and optionally being carboxylated.
It is however possible to envisage the use of other organic polymers capable of crosslinking and forming a three-dimensional network such as urea-formaldehyde resins, phenol-formaldehyde resins or acrylic resins.
The surface density of the hydrophobic coating is generally between 280 and 500 g/m?, preferably between 300 and 450 g/m?, in particular between 310 and 400 g/m?.
Another subject of the present invention is a thermal insulation product, in board form, comprising (a) a foam board, and (b) a facing product comprising a glass veil bonded by an elastomer binder as described above, the facing product (b) being fastened to at least one of the main faces of the foam board (a), preferably to the two main faces of the foam board.
The glass veil is preferably directly in contact with the foam forming the foam board, without any intermediate layer, such as an adhesive layer, being present.
6 EP3 555 190
The foam is advantageously an inelastic foam, preferably a phenol-formaldehyde foam, commonly used in the field of the thermal insulation of buildings and available for example under the name Kooltherm from Kingspan.
The thermal insulation product preferably has a thickness of between 30 and 200 mm and a density of between 20 and 45 kg/m”.
When the facing product used for covering the foam boards comprises a hydrophobic coating, this coating advantageously covers the whole of the surface of the facing product and therefore of the foam board.
A further subject of the invention is a process for manufacturing a thermal insulation product as described above, said process comprising the casting of a thermosetting expandable composition on a facing product according to the invention, and the heating of the thermosetting expandable composition.
When the surfacing product comprises a hydrophobic coating comprising from 10 i to 25 % by weight of a crosslinked organic polymer and from 75 to 90 % by weight of mineral particles, the thermosetting expandable composition is cast on the face of the facing product opposite the one bearing the hydrophobic coating.
A final subject of the present invention is an external thermal insulation composite system, installed against the outside face of a building facade and comprising, in 0 order, from the facade outward: - a layer of adhesive mortar, - a thermal insulation product as described above, - a layer of finishing mortar.
Examples
In order to develop a facing product having both alkali resistance and sufficient fire resistance, the inventors firstly tested several polymer binders, then several flame retarders.
NNN
Table 1 shows all of the organic binders tested.
7 EP3 555 190
Supplier Trade name Chemical nature Solids | Tg content | (°C)
Synthomer | Litex® S 9074 | Anionic aqueous dispersions of | 50 % - a self-crosslinking carboxylated 11 °C styrene-butadiene copolymer
Litex® S 9076 | Anionic aqueous dispersions of | 47 % - > a self-crosslinking carboxylated 44 °C styrene-butadiene copolymer
Celanese | Vinacryl® Ethyl acrylate/methyl 50 % 19 °C 4025 methacrylate copolymer
Prefere Dynea® Urea-formaldehyde resin 60 %
Resins Prefere
Wacker Vinnapas® Dispersion of a self-crosslinking | 51- 10 °C 192 ethylene/vinyl acetate 53 % copolymer (EVA)
Vinnapas® Dispersion of a self-crosslinking | 49-
EN1020 ethylene/vinyl acetate 51 % copolymer (EVA)
BASF Acronal& 280 | Cationic dispersion of a 40 % 20°C
KD copolymer of acrylic esters
Acronal® S559 | Aqueous dispersion of an 50 % acrylic polymer
Acrodur® Solution of a poly(carboxylic 50 % >100
DS3530 acid) and of a polyol °C (crosslinking agent)
Afacing product was manufactured with each of these resins by impregnating a wetlaid glass veil (made of E glass fibers) having, in the unbonded state, a grammage of 55 g/m?. The amount of polymer binder is, for all the samples, equal to around 20-25 % (LOI, loss on ignition).
The tensile strength is determined firstly for all the bonded veils in the following manner:
Measurement of the tensile strength
The tensile strength is determined using an MTS Insight® 30 kN device on samples of 5 cm x 30 cm. The samples are fastened in the device so that the initial distance between the two jaws is 20 cm. The pull rate is 40 mm/minute. The tensile strength is the maximum force recorded before the sample breaks.
8 EP3 555 190
The tests are carried out at a temperature of 23*C and a relative humidity of 50 %.
Each value is the average of 10 samples tested.
Next, the resistance of the samples to alkalis and to moisture is evaluated. For this, the tensile strength is measured before and after an accelerated aging test comprising the immersion of the samples in an alkaline solution or in water. The resistance to alkaline materials was tested following two different protocols.
Alkali aging test - ETAG 004 protocol
Precut samples (5 cm x 30 cm) are immersed for 28 days in an alkaline solution (prepared by dissolving 2 g of CaOHz, 4 g of NaOH and 16 g of KOH in 4 liters of water) at a temperature of 23 °C in a suitable container. At the end of 28 days, the alkaline solution is replaced by an equivalent volume of an acid solution (containing 0.05 % HCI). After 5 minutes of neutralization, the samples are washed three times 5 minutes with an identical volume of water, then are dried for 48 i hours at a temperature of 23 *C andat a relative humidity of 50 %.
Alkali aging test — DIBT protocol
Precut samples (5 cm x 30 cm) are immersed for 6 hours in an alkaline solution (prepared by completely dissolving 2.06 g of CaOHz, 3.77 g of NaOH and 14.80 g of KOH in 4.29 liters of water) at a temperature of 60 *C in a suitable container. At the end of 6 hours, the samples are washed for 5 minutes with water, then dried for 1 hour at a temperature of 60 °C. After drying, the samples are kept at 23 °C and at a relative humidity of 50 %.
Wet aging
Precut samples (5 cm x 30 cm) are immersed for 10 minutes in deionized water at a temperature of 80 ”C in a suitable container, then removed from the water. The tensile strength measurement is carried out as soon as possible on the still wet samples, i.e. without prior drying.
Table 2 shows the tensile strengths before and after alkali and water aging and the 0 retention percentages (between parentheses).
9 EP3 555 190
Table 2
Retention of the tensile strength after wet and alkali aging of the facing products
Binder Initial tensile | Wet aging - Alkali aging - Alkali aging - strength - in in N/5 cm | DIBT protocol -in ETAG 004
N/5 cm (%) N/5 cm (%) protocol — in
N/5 cm (960)
Litex® S 9074 111 (82 %) 89 (66 %) 99 (73 %)
Litex® S 9076 79 (69 %) 77 (68 %) 82 (72 %)
Vinacryl® 15 (15 %) 4025
Acronal& 280 150 13 (9 %) 15 (10 %) 25 (17 %) [KD
Acronal& 53 25 (49 %) 52 (98 %) 53 (100 %)
S559
Acrodur® 148 50 (33 %)
DS3530
Vinnapas® 130 75 (60 %) 51 (41 %) 130 (100 %) 192 |Vinnapas& 67 (74 %) 44 (49 %) 51 (57 %)
EN1020
Prefere 120 46 (55 %) 13 (15 %)
Resins
The above results show that only the binders based on carboxylated styrene- butadiene rubber make it possible to retain a tensile strength greater than 50 % of the initial value for the three aging tests taken into consideration.
The development of a facing product having sufficient fire resistance was therefore continued with these elastomers.
Various retarders were introduced into the self-crosslinking SBR latex Litex? S 9074 in an amount of 10 % by dry weight. The facing products bonded by 25 % (LOI) of elastomer binder (SBR + flame retardant) were subjected to a reaction to fire test according to the standard ISO 11925-2 (ignitability of products subjected to the impingement of a single flame source).
EP3 555 190
Table 3
Content of Fire Retention of the tensile strength
Flame retarder flame resistance retarder test (ETAG 004 protocol)
Ammonium > | sulfamate* 10 % successful 60 % (OK)
Ammonium polyphosphate*** 10 % failure 75 (OK) * Bemiflame PF (Schmits) **Aflammit PCI 202 (Thor) ***Aflamit PMN 500 (Thor) 10 Table 3 shows that only ammonium sulfamate gives the facing products a satisfactory fire resistance. This flame retarder was incorporated into the binder at various concentrations ranging from 5 to 20 % by weight.
The results of these tests, presented in table 4 below, show that an increasing concentration of ammonium sulfamate reduces the alkali resistance of the facing product. At 20 % by weight of ammonium sulfamate, this alkali resistance is still more or less satisfactory (i.e. greater than 50 %), but unexpectedly the fire resistant of a facing product containing a strong concentration of this retarder is insufficient.
Table 4 = Content of Fire Retention of the tensi
Flame retarder ontent © resistance elention of the tensile flame retarder test strength (ETAG 004 protocol)
Ammonium 5% failure 77 % (OK) sulfamate
Ammonium 10 % successful 60 % (OK) sulfamate | Ammonium 15 % successful 65 % (OK) sulfamate
Ammonium 20 % failure 54 % (OK) sulfamate —

Claims (14)

1 EP3 555 190 TULEN- JA EMÄKSENKESTÄVÄ PINNOITUSTUOTE VAAHTOMUOVILEVYILLE PATENTTIVAATIMUKSET1 EP3 555 190 FIRE AND ALKALI RESISTANT COATING PRODUCT FOR FOAM PLASTIC SHEETS PATENT CLAIMS 1. Vaahtomuovilevyjen pinnoitustuote, joka käsittää elastomeerisideaineella sidotun lasikuituharson, tunnettu siitä, että elastomeerisideaine sisältää: (a) orgaanista elastomeeriä, joka on itsesilloittuva styreenibutadieenimetakrylaattikumi, jolla on anionisia karboksylaattifunktioita, ja (b) 8—18 paino-% ammoniumsulfamaattia orgaanisen elastomeerin ja ammoniumsulfamaatin kokonaismäärästä.1. A coating product for foam plastic sheets comprising glass fiber mesh bonded with an elastomeric binder, characterized in that the elastomeric binder contains: (a) organic elastomer, which is a self-crosslinking styrene butadiene methacrylate rubber with anionic carboxylate functions, and (b) 8-18% by weight of ammonium sulfamate of the total amount of organic elastomer and ammonium sulfamate . 2. Patenttivaatimuksen 1 mukainen pinnoitustuote, tunnettu siitä, että elastomeerisideaine sisältää 9—17 paino-% ammoniumsulfamaattia orgaanisen elastomeerin ja ammoniumsulfamaatin kokonaismäärästä.2. Coating product according to claim 1, characterized in that the elastomer binder contains 9-17% by weight of ammonium sulfamate of the total amount of organic elastomer and ammonium sulfamate. 3. Patenttivaatimuksen 2 mukainen pinnoitustuote, tunnettu siitä, että elastomeerisideaine sisältää 10-15 paino-% ammoniumsulfamaattia orgaanisen elastomeerin ja ammoniumsulfamaatin kokonaismäärästä.3. Coating product according to claim 2, characterized in that the elastomer binder contains 10-15% by weight of ammonium sulfamate of the total amount of organic elastomer and ammonium sulfamate. 4. Jonkin edellisen patenttivaatimuksen mukainen pinnoitustuote, tunnettu siitä, että elastomeerisideaineen määrä suhteessa sitoutumattoman lasikuituharson painoon on 15—40 paino-%, edullisesti 20-30 paino-%.4. The coating product according to one of the preceding claims, characterized in that the amount of elastomer binder in relation to the weight of the unbound glass fiber gauze is 15-40% by weight, preferably 20-30% by weight. 5. Jonkin edellisen patenttivaatimuksen mukainen pinnoitustuote, tunnettu siitä, että sitoutumattoman lasikuituharson pinta-alamassa on 30-350 g/m?, — edullisesti 40-250 g/m? edullisemmin 50—100 g/m? ja ihanteellisesti 55-80 g/m?.5. A coating product according to one of the preceding claims, characterized in that the surface mass of the unbound glass fiber gauze is 30-350 g/m?, — preferably 40-250 g/m? preferably 50—100 g/m? and ideally 55-80 g/m?. 6. Jonkin edellisen patenttivaatimuksen mukainen pinnoitustuote, tunnettu siitä, että se käsittää lisäksi vain yhdellä pinnoistaan hydrofobisen päällysteen, joka käsittää 10-25 paino-% silloitettua orgaanista polymeeriä ja 75— 90 paino-% mineraalipartikkeleita.6. A coating product according to one of the preceding claims, characterized in that it also comprises a hydrophobic coating on only one of its surfaces, which comprises 10-25% by weight of cross-linked organic polymer and 75-90% by weight of mineral particles. 7. Patenttivaatimuksen 6 mukainen pinnoitustuote, tunnettu siitä, että silloitettu orgaaninen polymeeri on styreenibutadieenikumia (SBR) ja että mineraalipartikkelit ovat kalsiumkarbonaattipartikkeleita, edullisesti7. Coating product according to claim 6, characterized in that the crosslinked organic polymer is styrene butadiene rubber (SBR) and that the mineral particles are calcium carbonate particles, preferably 2 EP3 555 190 kalsiumkarbonaattipartikkeleita, jotka on tehty hydrofobisiksi rasvaketjuja oksastamalla.2 EP3 555 190 calcium carbonate particles made hydrophobic by grafting fatty chains. 8. Patenttivaatimuksen 6 tai 7 mukainen pinnoitustuote, tunnettu siitä, että hydrofobisen päällysteen pinta-alamassa on 280-500 g/m?, edullisesti 300— 450g/m? erityisesti 310-400 g/m.8. A coating product according to claim 6 or 7, characterized in that the surface mass of the hydrophobic coating is 280-500 g/m², preferably 300-450 g/m². especially 310-400 g/m. 9. Lämmöneristetuote, joka käsittää: - vaahtomuovilevyn ja - jonkin edellisen patenttivaatimuksen mukaisen pinnoitustuotteen, joka käsittää elastomeerisideaineella sidotun lasikuituharson, joka pinnoitustuote on kiinnitetty ainakin yhteen vaahtomuovilevyn pääpinnoista, edullisesti kahteen vaahtomuovilevyn pääpinnoista.9. A thermal insulation product comprising: - a foam plastic sheet and - a coating product according to one of the preceding claims, which comprises glass fiber gauze bonded with an elastomer adhesive, which coating product is attached to at least one of the main surfaces of the foam plastic sheet, preferably to two of the main surfaces of the foam plastic sheet. 10. Patenttivaatimuksen 9 mukainen lämmöneristetuote, tunnettu siitä, että lasikuituharso on suoraan kosketuksissa vaahtomuovilevyn muodostavaan vaahtoon.10. Thermal insulation product according to claim 9, characterized in that the glass fiber gauze is in direct contact with the foam forming the foam plastic sheet. 11. Patenttivaatimuksen 9 tai 10 mukainen lämmöneristetuote, tunnettu siitä, että vaahto on ei-elastista vaahtoa, edullisesti fenoli- formaldehydivaahtoa.11. Thermal insulation product according to claim 9 or 10, characterized in that the foam is non-elastic foam, preferably phenol-formaldehyde foam. 12. Menetelmä patenttivaatimusten 9—11 mukaisen lämmöneristetuotteen valmistamiseksi, joka käsittää lämpökovettuvan paisuvan koostumuksen valamisen jonkin patenttivaatimuksista 1-8 mukaisen pinnoitustuotteen päälle ja lämpökovettuvan paisuvan koostumuksen kuumentamisen.12. A method for manufacturing a thermal insulation product according to claims 9-11, which comprises pouring a thermosetting intumescent composition on top of a coating product according to one of claims 1-8 and heating the thermosetting intumescent composition. 13. Patenttivaatimuksen 12 mukainen valmistusmenetelmä, tunnettu siitä, että kun pinnoitustuote käsittää hydrofobisen päällysteen, joka käsittää 10-25 paino-% silloitettua orgaanista polymeeriä ja 75-90 paino-% mineraalipartikkeleita, paisuva ja lämpökovettuva koostumus on valettu —pinnoitustuotteen sen pinnan päälle, joka on hydrofobista päällystettä kannattelevaa pintaa vastapäätä.13. The manufacturing method according to claim 12, characterized in that when the coating product comprises a hydrophobic coating comprising 10-25% by weight of cross-linked organic polymer and 75-90% by weight of mineral particles, the swelling and thermosetting composition is cast on the surface of the coating product which is opposite the surface supporting the hydrophobic coating. 3 EP3 555 1903 EP3 555 190 14. Ulkoinen lämmöneristekomposiittijärjestelmä, joka on asennettu rakennuksen julkisivun ulkopintaa vasten ja joka käsittää järjestyksessä julkisivusta ulospäin: - liimalaastikerroksen, - patenttivaatimusten 9—11 mukaisen lämmöneristetuotteen, - viimeistelylaastikerroksen.14. External thermal insulation composite system, which is installed against the outer surface of the facade of the building and which comprises, in order from the facade outwards: - an adhesive mortar layer, - a thermal insulation product according to patent claims 9—11, - a finishing mortar layer.
FIEP17825571.7T 2016-12-16 2017-12-12 Fire-resistant and alkali-resistant surfacing product for foam boards FI3555190T3 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR1662649A FR3060575B1 (en) 2016-12-16 2016-12-16 FIRE AND ALKALI RESISTANT SURFACING PRODUCT FOR FOAM PLATES
PCT/FR2017/053520 WO2018109363A1 (en) 2016-12-16 2017-12-12 Fire-resistant and alkali-resistant surfacing product for foam boards

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FI (1) FI3555190T3 (en)
FR (1) FR3060575B1 (en)
WO (1) WO2018109363A1 (en)

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JP2006213881A (en) * 2005-02-07 2006-08-17 Teraoka Seisakusho:Kk Self-adhesive tape

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EP3555190A1 (en) 2019-10-23
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WO2018109363A1 (en) 2018-06-21
EP3555190B1 (en) 2023-11-01

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