FRP

Each DreaM Inc. non-combustible FRP actually an FRC (Fiber Reinforced Ceramics). It is developed based on water-soluble fiber-reinforced ceramics and reinforced with basalt cloth.

This product is resin-free, and its component is all non-flammable; thus, it is wholly non-combustible and poison gas-free.

Since this new material has the same nature and characteristics as the pre-existing FRP (fiber reinforced plastic) and could be used in the same manner, we call this new material next-generation FRP (tentative name) for convenience.

Mr. Hamamura, developer and chairman of the board, is a specialist who has worked with FRP for over 40 years. He has simulated various situations for its development and possesses the knowledge and experience to overcome needed criteria and challenging problems. The quality of the next-generation FRP (tentative name) progresses every day.

Flame-retardant FRP that has passed ISO-5660 is commonly called nonflammable FRP, but it is easily ignited by a weak flame of a lighter and produces toxic gases. When burned with a burner, it burns violently.

The next-generation FRP developed by our company does not burn at all even with a burner flame of 1,200°C and does not emit toxic gases at all.

We have also tried burning cardboard laminated with next-generation FRP, and even the cardboard does not burn because of its low thermal conductivity.

Developing non-combustible FRP was the most extended dream in the FRP industry.
Each DreaM Inc. has succeeded in creating the world’s first non-combustible FRP that has passed the ISO 1182 test.

As seen in the video, it can withstand a 1200 ℃ (2192 °F) burner fire even being 0.8 mm (ca. 0.031 in.) thin. The melting point of aluminum is 660℃ (1220 °F), but our product will bear against 1200 ℃ (2192 °F) fire without deformation. Depending on its use, it can replace aluminum. Its potential is limitless as you can modify them into any shape,

Non-combustible FRP (next-generation FRP) is easy to pulverize and recycle, another different feature from the pre-existing FRP (fiber reinforced plastic).

The left image shows a 1 mm (ca. 0.039 in.) and 6 mm (ca. 0.236 in.) powder for recycling. The bottom is the pulverized form. The top is pulverized and baked.

There are 3 ways to recycle.
１．Dispose of by mixing the powdered form with dirt (it is harmless).
２．Reuse by pulverizing and mixing into base material for another next-generation FRP.
３．Add to cement to reinforce concrete strength.

Pre-existing FRP (fiber reinforced plastic) is usually hard to separate and difficult to recycle, dispose of, and bad for the environment.
Non-combustible FRP (next-generation FRP), as mentioned above, is not only non-flammable but can be recycled in 3 easy ways, adding eco-friendly merit.

The General Building Research Corporation Of Japan conducted the ISO 5660 test for our next-generation FRP (tentative name) on July 3, 2020, and it has passed with overwhelming results.

“ISO 5660” also called the railway non-combustible test, is used as criteria for railway materials. Soon, FRP that passes this standard has been called non-combustible FRP.

【Details of exothermic testing】
Exothermic testing of “ISO 5660” is as below.
The test body is exposed to an external ignitor and radiant heat ( 10~100 kW/㎡ range )  under an air environment. It is then ignited and burned. Oxygen concentration in the exhausted combustion gas and the flow rate of the exhaust gas is then measured. The heat generation rate is determined by the oxygen-consuming method.

【Exothermic testing evaluation point】
１．The gross heating value is under 8 MJ/㎡ after 20 minutes of heating.
２．No fatal cracks or holes for fire protection both inside and out after 20 minutes of heating.
３．Heat generation rate is under 200 kW/㎡ for 10 continuous seconds or more.

When you look at the numbers, the gross heating value is a mere 0.01 MJ/㎡, and the maximum heat generation rate is 0.33 kW/㎡, which on the graph is nearly a zero. It is completely non-flammable, and its shape unchanged. These numbers confirm the material’s unprecedented performance.

Test number: III C-20-0046
Test name: Exothermic test (cone calorimeter test)
Test date: July 3, 2020
Test body: Next-generation FRP (tentative name)

Our next-generation FRP (tentative name) receives non-combustible evaluation.
【Test Method】

Combustion test for non-metal railway vehicle materials is as below.
A 182 mm x 257 mm sample material is kept at a 45-degree angle on a low heat-conducting material like a cork to keep the bottom center of the combustion vessel 25.4 mm vertically below the center of the sample’s burning side (bottom face). 0.5 cc of pure ethyl alcohol is poured in and ignited, then left until it is completely burnt.
Combustion evaluation is sectioned in during alcohol combustion and after combustion. In the former, an observation was made on the sample ignition, catch flame, and the state of the fumes and flames. In the latter were examined the after-flame, after-glow, carbonization, and deformation.
　

Temperature 25 ℃,　humidity 61 %,　duration of alcohol combustion 1 h 42 sec.

Evaluation：　Non-combustible
　

Certification Authority: Japan Railway Rolling Stock & Machinery Association
Test number: vehicle material combustion test 2020-450K
Test name: Combustion test for railway vehicle material
Test date: August 31, 2020
Test body: Next-generation FRP (tentative name)

Our next-generation FRP has cleared the cone calorie meter exothermic test of the combustion test for railway vehicle material.
Only materials evaluated as non-combustible in the railway vehicle material combustion test can qualify for this test.

You can see the overwhelming results on the left.

【Test method】
Test method is as below, based on those of ISO 5660-1: 2002.
An approx. 100 mm square sample with a maximum thickness of 50mm and a smooth surface is put under heat radiation of 50 kW/㎡for 10 minutes. Gross heat value (MJ/㎡), maximum heat generation rate (kW/㎡), and the time to ignition (seconds) are measured in this test to evaluate combustion.

【Pass verdict】
Below are the criteria

1）Gross heat value is under 8 MJ/㎡, and the maximum heat generation rate is under 300 kW/㎡.
2）If gross heat value is over 8 MJ/㎡ and under 30 NJ/㎡, ignition time is over 60 seconds, the maximum heat generation rate is under 300 kW/㎡.


Certification Authority: Japan Railway Rolling Stock & Machinery Association
Test number: Vehicle material combustion test 2020-27K
Test name: Corn calorimeter combustion thermic test
Test date: September 14, 2020
Test body: Next-generation FRP (tentative name)

[Hazard Information]
・Harmful when swallowed.
・Severe chemical burn on skin and damage to the eye.

[Safety Precautions]
・Wear protective gloves/ gears/ glass/ face shield.
・Do not inhale dust or mist.
・Do not eat, drink, or smoke while using this product.
・Wash hands thoroughly after use.

[First Aid]
・If in eyes: Rinse carefully in clean water for few minutes. Remove contact lenses if present and continue rinsing eyes. If irritation persists, call a doctor.
・If on skin: Rinse immediately with running water or shower.
・If on clothes: Immediately take off all contaminated clothing and remove product. Wash clothing if reusing.
・If swallowed: Rinse mouth. Do not force vomiting. Consult a doctor if feeling nauseous.
・If inhaled: Move person to a fresh air environment and rest in an easy to breathe position.

[Storage]
・Make sure the container is sealed and kept in a ventilated area.


＊The product label contains our selling agent company and our company’s name. Image is the version of Kyowa Inc.