Fire resistant and high temperature insulating composition

• US 5,338,349 A
• Filed: 05/24/1993
• Issued: 08/16/1994
• Est. Priority Date: 08/27/1992
• Status: Expired due to Term

• Current Assignee: Firecomp Incorporated
• Original Assignee: Firecomp Incorporated
• Inventors: Farrar, Randolph C.
• Primary Examiner(s): GREEN, ANTHONY J
• Application Number:
  US08/066,471
• Time in Patent Office: 449 Days
• Field of Search: 106/15.05, 106/18.12, 106/711, 106/803, 106/805, 106/811, 106/814, 106/817, 106/DIG. 2, 106/DIG. 3, 252/62, 252/601, 252/604, 428/289, 428/411.1, 428/428, 428/446, 428/457, 428/537.1, 428/537.5, 428/537.7, 428/702, 428/703, 428/920, 428/921
• US Class Current: 106/18.12
• CPC Class Codes: C04B 14/04 Silica-rich materials; Silicates
• CPC Class Codes: C04B 14/042 Magnesium silicates, e.g. talc, sepiolite
• CPC Class Codes: C04B 14/10 Clay sepiolite C04B14/042; grog C04B18/025
• CPC Class Codes: C04B 14/18 Perlite
• CPC Class Codes: C04B 14/20 Mica; Vermiculite mechanical splitting B28D
• CPC Class Codes: C04B 14/26 Carbonates
• CPC Class Codes: C04B 14/28 of calcium
• CPC Class Codes: C04B 18/24 Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper , cork
• CPC Class Codes: C04B 18/241 Paper, e.g. waste paper; Paper pulp
• CPC Class Codes: C04B 2103/0051 Water-absorbing polymers, hydrophilic polymers
• CPC Class Codes: C04B 2103/0062 Cross-linked polymers
• CPC Class Codes: C04B 2103/445 Gelling agents
• CPC Class Codes: C04B 2103/69 Fungicides
• CPC Class Codes: C04B 2111/00482 Coating or impregnation materials
• CPC Class Codes: C04B 2111/28 Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• CPC Class Codes: C04B 22/10 containing carbon in the anion
• CPC Class Codes: C04B 22/148 Aluminium-sulfate
• CPC Class Codes: C04B 24/02 Alcohols; Phenols; Ethers
• CPC Class Codes: C04B 24/2623 Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 24/2641 Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 24/38 : Polysaccharides or derivatives thereof C04B24/243 takes precedence
• CPC Class Codes: C04B 24/383 : Cellulose or derivatives thereof
• CPC Class Codes: C04B 26/04 : obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: C04B 28/02 : containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C09D 5/18 : Fireproof paints including high temperature resistant paints
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10S 106/02 : Perlite
• CPC Class Codes: Y10S 106/03 : Mica
• CPC Class Codes: Y10S 428/92 : Fire or heat protection feature
• CPC Class Codes: Y10S 428/921 : Fire or flameproofing
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31678 : Of metal
• CPC Class Codes: Y10T 428/31989 : Of wood
• CPC Class Codes: Y10T 428/31993 : Of paper
• CPC Class Codes: Y10T 428/31996 : Next to layer of metal salt [e.g., plasterboard, etc.]
• CPC Class Codes: Y10T 442/2631 : Coating or impregnation provides heat or fire protection

Abstract

A fire resistant and high temperature insulating composition is provided. The composition generally comprises a carbonate material in an amount from about 20% to about 80% by weight, an aluminosilicate in amount from about 0.5% to about 15% by weight, talc in amount from about 0.5% to about 10% by weight, cellulose in amount from about 1% to about 30% by weight, a binder in an amount from about 1% to about 45% by weight, and a gelling agent in an amount from about 1% to about 45% by weight. The binder is preferably a mixture of an organic adhesive such as a polymeric resin, and a non-organic adhesive such as cement, but other adhesives can be used alone or in combination therewith. The gelling agent is preferably a polymeric substance that swells in the presence of a liquid such as superabsorbent polymers. The components are combined and water may be added in an amount from about 1 to about 50% by weight to obtain a composition of the desired consistency. The composition can be used as a coating composition or it can be used to manufacture articles comprised of the composition.

Claims

1. A fire and heat resistant composition comprising:

a carbonate material in an amount from about 20% to about 80% by weight;

aluminosilicate in an amount from about 0.5% to about 15% by weight;

talc in an amount from about 0.5% to about 10% by weight;

cellulose in an amount from about 1% to about 30% by weight;

a binder in an amount from about 1% to about 45% by weight;

a gelling agent in an amount from about 1% to about 25% by weight.

2. The composition of claim 1 wherein the carbonate material is an alkaline earth metal carbonate or an alkali metal carbonate.

3. The composition of claim 2 wherein said alkaline earth metal carbonate or alkali metal carbonate is selected from the group consisting of CaCO₃, MgCO₃, and K₂ CO₃.

4. The composition of claim 3 wherein said composition contains a mixture of CaCO₃ or MgCO₃ in an amount from about 20% to about 80% by weight and K₂ CO₃ in an amount from about 0.5% to about 10% by weight.

5. The composition of claim 1 wherein the amount of the carbonate material is about 60% by weight.

6. The composition of claim 5 wherein the carbonate material is CaCO₃.

7. The composition of claim 2 wherein the carbonate material comprises CaCO₃ in an amount of about 57%, MgCO₃ in an amount of about 1.5%, and K₂ CO₃ in an amount of about 1.5%.

8. The composition of claim 1 further comprising aluminum sulfate in an amount from about 0.5% to about 5% by weight.

9. The composition of claim 1 wherein the binder is selected from the group consisting of non-organic cements, organic adhesives, and mixtures thereof.

10. The composition of claim 9 wherein the binder is present in an amount of about 25% by weight.

11. The composition of claim 10 wherein the binder comprises a mixture of masonry cement in an amount of about 22% by weight, polyvinyl acetate in an amount of about 2.5% by weight, polyvinyl alcohol in an amount of about 0.5% by weight and hydroxypropyl m-cellulose in an amount of about 1% by weight.

12. The composition of claim 1 wherein the aluminosilicate is elected from the group consisting of mica, clay and mixtures thereof.

13. The composition of claim 12 wherein the aluminosilicate is present in an amount of about 2% by weight.

14. The composition of claim 1 wherein said cellulose is selected from the group consisting of long-fiber cellulose and sawdust.

15. The composition of claim 14 wherein the cellulose is present in an amount of about 3% by weight.

16. The composition of claim 1 wherein the gelling agent is sodium polyacrylate in an amount of about 5% by weight.

17. The composition of claim 1 further comprising free water in an amount from about 1% to about 50% by weight.

18. The composition of claim 1 further comprising a fungicide.

19. A fire and heat resistant composition comprising:

calcium carbonate or magnesium carbonate in an amount from about 20 to about 60% by weight;

perlite in an amount from about 5 to about 20% by weight;

an aluminosilicate in an amount from about 1 to about 25% by weight;

talc in an amount from about 5 to about 15% by weight;

cellulose fiber in an amount from about 10 to about 25% by weight;

a binder in an amount from about 1 to about 25% by weight; and

a gelling agent in an amount from about 1 to about 10% by weight.

20. The composition as set forth in claim 19 wherein said binder comprises an organic adhesive.

21. The composition as set forth in claim 20 wherein said organic adhesive is present in the composition in an amount of about 15%.

22. The composition as set forth in claim 21 wherein said organic adhesive is a polyvinyl acetate or polyvinyl alcohol liquid resin.

23. The composition as set forth in claim 19 wherein said calcium carbonate or magnesium carbonate is present in an amount of about 30%.

24. The composition as set forth in claim 19 wherein said perlite is present in an amount of about 10%.

25. The composition as set forth in claim 19 wherein said aluminosilicate is selected from the group consisting of mica, clay and mixtures thereof.

26. The composition as set forth in claim 25 wherein said aluminosilicate comprises a combination of mica in an amount of about 10% and clay in an amount of about 5%.

27. The composition as set forth in claim 19 wherein said talc is present in an amount of about 10%.

28. The composition as set forth in claim 19 wherein said cellulose fiber is selected from the group consisting of long-fiber cellulose and sawdust.

29. The composition as set forth in claim 28 wherein said cellulose fiber is present in an amount of about 20%.

30. The composition as set forth in claim 19 further comprising water in an amount of about 1 to about 50% by weight.

31. The composition as set forth in claim 19 wherein said gelling agent is sodium polyacrylate.

32. The composition as set forth in claim 19 further comprising a fungicide.

33. A fire and heat resistant composition consisting essentially of:

calcium carbonate in an amount of about 57%;

magnesium carbonate in an amount of about 1.5%;

potassium carbonate in an amount of about 1.5%;

aluminosilicate in an amount of about 2%;

talc in an amount of about 2%;

cellulose fiber in an amount of about 3%;

polyvinyl acetate in an amount of about 2.5%;

polyvinyl alcohol in an amount of about 0.5%;

masonry cement in an amount of about 22%;

hydroxypropyl m-cellulose in an amount of about 1%;

aluminum sulfate in an amount of about 2%; and

sodium polyacrylate in an amount of about 5%.

34. A fire and heat resistant article comprising:

an article coated with a coating composition comprising;

a carbonate material in an amount from about 20% to about 80% by weight;

aluminosilicate in an amount from about 0.5% to about 15% by weight;

talc in an amount from about 0.5% to about 10% by weight;

cellulose in an amount from about 1% to about 30% by weight;

a binder in an amount from about 1% to about 45% by weight;

a gelling agent in an amount from about 1% to about by weight.

35. The coated article as set forth in claim 34 wherein said article is formed from plastic, rubber, wood, paper products, metal, concrete, glass, ceramic or fabric.

36. A rigid article formed of a composition comprising a carbonate material in an amount from about 20% to about 80% by weight;

aluminosilicate in an amount from about 0.5% to about 15% by weight;

talc in an amount from about 0.5% to about 10% by weight;

cellulose in an amount from about 1% to about 30% by weight;

a binder in an amount from about 1% to about 45% by weight;

a gelling agent in an amount from about 1% to about 25% by weight.