Multi-layer thermal insulation composite

• US 8,663,774 B2
• Filed: 04/21/2011
• Issued: 03/04/2014
• Est. Priority Date: 04/23/2010
• Status: Active Grant

• Current Assignee: Unifrax I LLC (ASP Unifrax Holdings, Inc.)
• Original Assignee: Unifrax I LLC (ASP Unifrax Holdings, Inc.)
• Inventors: Fernando, Joseph A., Miller, Kenneth B.
• Primary Examiner(s): O'HERN, BRENT T
• Application Number:
  US13/091,568
• Publication Number:
  US 20120107547A1
• Time in Patent Office: 1,048 Days
• Field of Search: 428/76, 428/68, 428/74, 428/473.5, 428/479.6, 428/530, 428/421, 428/422, 442/1
• US Class Current: 428/76
• CPC Class Codes: B32B 2262/0238 Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres
• CPC Class Codes: B32B 2262/0261 Polyamide fibres
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2571/00 Protective equipment
• CPC Class Codes: B32B 29/02 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 5/24 one layer being a fibrous or filamentary layer
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: C04B 2235/5232 Silica or silicates other than aluminosilicates, e.g. quartz
• CPC Class Codes: E04B 1/94 against fire fire protection of partitions E04B2/7403, E04B2/7409; supporting constructions for ceilings having the capability of expansion in case of fire E04B9/08; fire-fighting A62C, e.g. fire prevention or containment A62C2/00; impregnation of wood or similar materials B27K; fireproof paints C09D5/18; fireproofing materials C09K21/00; flame-resistant papers D21H5/0002; coverings or linings, e.g. for walls or ceilings, in general E04F13/00; fireproof doors E06B5/16; firebreak devices for pipes or the like passing through walls F16L5/04; protection of pipes by means of non-inflammable material F16L57/04
• CPC Class Codes: Y10T 29/49826 Assembling or joining
• CPC Class Codes: Y10T 428/23 Sheet including cover or casing
• CPC Class Codes: Y10T 428/237 Noninterengaged fibered material encased [e.g., mat, batt, etc.]
• CPC Class Codes: Y10T 428/239 Complete cover or casing
• CPC Class Codes: Y10T 428/249921 Web or sheet containing structurally defined element or component
• CPC Class Codes: Y10T 428/249969 Of silicon-containing material [e.g., glass, etc.]
• CPC Class Codes: Y10T 428/251 Mica
• CPC Class Codes: Y10T 428/3154 Of fluorinated addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31544 Addition polymer is perhalogenated
• CPC Class Codes: Y10T 428/31721 Of polyimide
• CPC Class Codes: Y10T 428/31783 : Paper or wood
• CPC Class Codes: Y10T 428/31964 : Paper
• CPC Class Codes: Y10T 442/10 : Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]

Abstract

A multilayer thermal insulation composite for fire protection applications. The composite includes a fibrous insulation layer, at least one inorganic heat absorbing layer disposed on one side of the fibrous insulation layer, and at least one superinsulation layer disposed on at least one side of the composite adjacent the heat absorbing layer or the fibrous insulation layer. The composite may further include a scrim layer comprising a high temperature resistant, flexible, woven or non-woven scrim or scrim and high temperature resistant material disposed around the multilayer thermal insulation composite partially or substantially totally encapsulating the composite. The composite is lightweight and flexible, exhibits reduced heat transfer to the cold-face, with improved thermal insulation capability.

Claims

1. A multilayer thermal insulation composite comprising:

at least one superinsulation layer; and

one or both of (i) at least one fibrous insulation layer comprising inorganic fibers or (ii) at least one inorganic heat absorbing layer, wherein said inorganic heat absorbing layer comprises one or both of (i) at least one intumescent layer or (ii) at least one endothermic layer.

2. The composite of claim 1 comprising:

at least one superinsulation layer; and

at least one fibrous insulation layer comprising inorganic fibers.

3. The composite of claim 1 comprising:

at least one superinsulation layer; and

at least one inorganic heat absorbing layer.

4. The composite of claim 1 comprising:

at least one superinsulation layer;

at least one fibrous insulation layer comprising inorganic fibers; and

at least one inorganic heat absorbing layer.

5. The composite of claim 1, further comprising a scrim layer disposed adjacent one or more of the layers of the composite, or disposed around the multilayer thermal insulation composite partially or totally encapsulating the composite.

6. The composite of claim 5, wherein the scrim layer comprises a scrim and a ceramic fiber or bio-soluble fiber paper.

7. The composite of claim 1, wherein the inorganic fibers comprise at least one of biosoluble inorganic fibers, conventional inorganic fibers, or mixtures thereof.

8. The composite of claim 7, wherein the conventional inorganic fibers comprise at least one of refractory ceramic fibers, mineral wool fibers, glass fibers, silica fibers, leached glass silica fibers, fiberglass, or mixtures thereof.

9. The composite of claim 8, wherein the refractory ceramic fibers comprise alumina-silica fibers.

10. The composite of claim 9, wherein the alumina-silica fibers comprise the fiberization product of about 45 to about 75 weight percent alumina and about 25 to about 55 weight percent silica.

11. The composite of claim 7, wherein the biosoluble inorganic fibers comprise alkaline earth silicate fibers.

12. The composite of claim 11, wherein the alkaline earth silicate fibers comprise at least one of calcium-magnesia-silicate fibers, magnesium-silicate fibers, or mixtures thereof

13. The composite of claim 12, wherein the magnesium-silicate fibers comprise the fiberization product of about 70 to about 86 weight percent silica, about 14 to about 30 weight percent magnesia and about 5 weight percent or less impurities.

14. The composite of claim 13, wherein the magnesium-silicate fibers comprise the fiberization product of about 70 to about 80 weight percent silica, about 18 to about 27 weight percent magnesia and 0 to 4 weight percent impurities.

15. The composite of claim 12, wherein the calcium-magnesia-silicate fibers comprise the fiberization product of about 45 to about 90 weight percent silica, greater than about 0 to about 45 weight percent calcia, and greater than 0 to about 35 weight percent magnesia.

16. The composite of claim 15, wherein the calcium-magnesia-silicate fibers comprise the fiberization product of about 60 to about 70 weight percent silica, from about 16 to about 35 weight percent calcia, and from about 4 to about 19 weight percent magnesia.

17. The composite of claim 16, wherein the calcium-magnesia-silicate fibers comprise the fiberization product of about 61 to about 67 weight percent silica, from about 27 to about 33 weight percent calcia, and from about 2 to about 7 weight percent magnesia.

18. The composite of claim 1, wherein the intumescent layer comprises from about 20 to about 50 weight percent intumescent substance, about 15 to about 50 weight percent heat resistant inorganic fiber, 0 to about 20 weight percent organic binder, and optionally 0 to about 50 weight percent char strength enhancer.

19. The composite of claim 18, wherein the intumescent substance comprises unexpanded vermiculite, expandable graphite, perlite, hydrobiotite, water-swelling tetrasilicic flourine mica, or mixtures thereof.

20. The composite of claim 19, wherein the intumescent substance comprises expandable graphite.

21. The composite of claim 18, wherein the char strength enhancer comprises alkali metal silicates, colloidal silica, colloidal alumina, inorganic acids, phosphates, or mixtures thereof.

22. The composite of claim 21, wherein the char strength enhancer comprises an alkali metal silicate.

23. The composite of claim 22, wherein the alkali metal silicate comprises sodium silicate.

24. The composite of claim 1, wherein the endothermic layer comprises from 0 to less than about 50 weight percent binder;

from 0 to about 90 weight percent inorganic fiber;

from 0 to about 50 weight percent endothermic filler, and optionally from 0 to about 20 weight percent opacifier, based on the total weight of the endothermic layer.

25. The composite of claim 1, wherein the endothermic layer comprises about 5 weight percent binder, about 85 weight percent inorganic fiber, about 5 weight percent endothermic filler and optionally about 5 weight percent opacifier, based on the total weight of the endothermic layer.

26. The composite of claim 24, wherein the endothermic filler comprises alumina trihydrate, magnesium carbonate hydrated cements, hydrated zinc borate, calcium sulfate, magnesium ammonium phosphate, magnesium hydroxide or mixtures thereof.

27. The composite of claim 24, wherein the weight ratio of endothermic filler to inorganic fiber is in the range of about 0.25:

1 to 30;

1.

28. The composite of claim 1, wherein the superinsulation layer comprises finely divided metal oxide having a BET surface area of about 50 to about 700 g/m² and an opacifier, optionally reinforcing inorganic fibers and, optionally a binder.

29. The composite of claim 28, wherein the finely divided metal oxide comprises at least one of microporous silica, microfiber glass, pyrogenic silicas, arc silicas, low-alkali precipitated silicas, silicon dioxide aerogels, pyrogenic aluminum oxides, arc aluminum oxides, low-alkali precipitated aluminum oxides, aluminum oxide aerogels, or mixtures thereof.

30. The composite of claim 28, wherein the opacifier comprises at least one of ilmenite, titanium dioxide, iron(II)/iron(III) mixed oxides, chromium dioxide, zirconium oxide, manganese dioxide, iron oxide, rutile, zirconium silicate, silicon carbide, or mixtures thereof.

31. The composite of claim 28, wherein the reinforcing inorganic fibers comprise at least one of aluminum silicate fibers, magnesium silicate fibers, calcium-magnesium-silicate fibers, rockwool fibers, textile glass fibers, quartz fibers, or combinations thereof.

32. The composite of claim 28, wherein the superinsulation layer comprises silicon dioxide and zirconium silicate, and optionally a reinforcing glass fiber.

33. The composite of claim 1, wherein the superinsulation layer has a specific heat capacity of about 0.8 KJ/kgK for temperatures from about 20°

C. to about 800°

C.

34. The composite of claim 1, wherein the superinsulation layer has a modulus of elasticity of greater than about 3 MPa for strains less than 0.02, and has a bulk density of greater than or equal to about 260 kg/m³.

35. The composite of claim 1, wherein the superinsulation layer has a thermal conductivity less than 0.055 W/mK for mean temperatures less than 1000°

C.

36. The composite of claim 1, wherein the superinsulation layer has a bulk density between about 25 kg/m³ and about 500 kg/m³.

37. The composite of claim 1, wherein the fibrous insulation layer and the inorganic heat absorbing layer each comprise an opacifier.

38. The composite of claim 1, wherein at least two layers of the multilayer thermal insulation composite are affixed together with at least one of an adhesive, needle bonding, or stitching.