Flame resistant insulating fabric compositions prepared by plasma spraying

• US 4,357,387 A
• Filed: 01/12/1982
• Issued: 11/02/1982
• Est. Priority Date: 08/20/1981
• Status: Expired due to Fees

• Current Assignee: Label-Aire, Inc. (Cenveo Incorporated)
• Original Assignee: Subtex, Inc.
• Inventors: George, Stephen, George, Thomas H.
• Primary Examiner(s): VAN BALEN, WILLIAM
• Application Number:
  US06/338,853
• Time in Patent Office: 294 Days
• Field of Search: 427/34, 427/423, 428/246, 428/251, 428/253, 428/254, 428/284, 428/285
• US Class Current: 442/71
• CPC Class Codes: C04B 30/02 containing fibrous materials
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/4505 characterised by the method of application
• CPC Class Codes: C04B 41/5025 with ceramic materials copper oxide or solid solutions thereof C04B41/5074
• CPC Class Codes: D04H 11/00 Non-woven pile fabrics layered products forming non-woven pile fabrics B32B
• CPC Class Codes: D06M 10/06 Inorganic compounds or elements
• CPC Class Codes: D06N 7/0042 Conductive or insulating layers; Antistatic layers; Flame-proof layers
• CPC Class Codes: Y10T 442/2098 At least two coatings or impregnations of different chemical composition
• CPC Class Codes: Y10T 442/2631 Coating or impregnation provides heat or fire protection
• CPC Class Codes: Y10T 442/273 Coating or impregnation provides wear or abrasion resistance

Abstract

Refractory coated fabric compositions having a thickness substantially thinner than those prepared heretofore can be provided by forming the refractory coating by a plasma spraying technique.

Claims

1. A method of preparing a flexible refractory coated fabric composition which comprises:

(a) developing a thermal plasma spray,

(b) introducing finely divided refractory materials into said thermal plasma spray, and

(c) directing said thermal plasma spray at the exposed surface of a non-rigid base fabric whereby a coating of said refractory materials is formed on said fabric, said refractory materials being capable of fusing with said fabric at elevated temperatures.

2. A method according to claim 1 wherein the coating of said refractory materials has a thickness of between about 1 and about 10 mils.

3. A method according to claim 2 wherein the thickness is between about 1 and about 3 mils.

4. A method according to claim 1 wherein the coating of refractory materials comprises a light density layer and a heavier density layer.

5. A method according to claim 1 including the following additional step:

(d) forming an abrasion resistant polymeric coating on the outer surface of said coating of said refractory materials.

6. A method according to claim 1 including the following additional step:

(e) applying an adhesive to the outer surface of said coating of said refractory materials.

7. A method according to claim 1 wherein the coating of said refractory materials is formed on both sides of said fabric.

8. A method according to claim 7 including the following additional steps:

(f) forming an abrasion resistant polymeric coating on the outer surface of one of the coatings of said refractory materials, and

(g) applying an adhesive to the outer surface of the other coating of said refractory materials.

9. A method according to claim 1 wherein the non-rigid base fabric is a woven fabric.

10. A method according to claim 1 wherein the non-rigid base fabric is a knitted fabric or a non-woven web.

11. A method according to claim 9 wherein the base fabric is made from fiberglass yarn, Kevlar yarn or a mixture of fiberglass yarn and Kevlar yarn.

12. A method according to claim 10 wherein the base fabric is made from fiberglass yarn, Kevlar yarn or a mixture of fibeglass yarn and Kevlar yarn.

13. A method according to claim 1 wherein the refractory materials are alumina, zirconia, calcium silicate, silicon dioxide or mixtures thereof.

14. A method according to claim 1 wherein the refractory materials are silicon carbide, or thermal carbon black.

15. A method according to claim 1 wherein the base fabric is woven, knitted or non-woven and is made from quartz yarn or a mixture of quartz yarn and Kelvar yarn.

16. A method according to claim 1 wherein the base fabric is a non-woven web or paper of alumina silica fibers, alumina fibers, zirconia fibers or mixtures thereof.

17. A refractory coated fabric composition prepared according to the method of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15 or 16.