Composite flame barrier laminate for a thermal and acoustic insulation blanket

• US 8,607,926 B2
• Filed: 12/14/2011
• Issued: 12/17/2013
• Est. Priority Date: 04/21/2009
• Status: Active Grant

• Current Assignee: DuPont Safety & Construction, Inc. (DuPont de Nemours, Inc.)
• Original Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Inventors: Richardson, Llewellyn Bentley III, Kawka, Dariusz Wlodzimierz
• Primary Examiner(s): Warren, David
• Assistant Examiner(s): Russell, Christina
• Application Number:
  US13/325,741
• Publication Number:
  US 20120321848A1
• Time in Patent Office: 734 Days
• Field of Search: 181/294, 428/138, 428/212, 428/213, 428/216, 428/341
• US Class Current: 181/294
• CPC Class Codes: B32B 19/045 of synthetic resin
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2255/205 Metallic coating
• CPC Class Codes: B32B 2264/10 Inorganic particles
• CPC Class Codes: B32B 2264/107 Ceramic
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2371/00 Polyethers, e.g. PEEK, i.e. polyether-etherketone; PEK, i.e. polyetherketone
• CPC Class Codes: B32B 2379/08 Polyimides
• CPC Class Codes: B32B 2439/00 Containers; Receptacles closures therefor B32B2435/00
• CPC Class Codes: B32B 2605/18 Aircraft blades, propellers B32B2603/00
• CPC Class Codes: B32B 27/14 next to a particulate layer
• CPC Class Codes: B32B 27/285 comprising polyethers
• CPC Class Codes: B32B 3/266 characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B64C 1/40 Sound or heat insulation , e.g. using insulation blankets
• CPC Class Codes: C04B 14/202 Vermiculite
• CPC Class Codes: C04B 2237/30 Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
• CPC Class Codes: C04B 2237/341 : Silica or silicates
• CPC Class Codes: C04B 35/63456 : Polyurethanes; Polyisocyanates
• CPC Class Codes: C04B 35/6346 : Polyesters
• CPC Class Codes: C04B 35/63468 : Polyamides
• CPC Class Codes: C04B 37/008 : by means of an interlayer consisting of an organic adhesive, e.g. phenol resin or pitch
• CPC Class Codes: C09J 177/00 : Adhesives based on polyamides obtained by reactions forming a carboxylic amide link in the main chain based on polyhydrazides C09J179/06; based on polyamide-imides C09J179/08; Adhesives based on derivatives of such polymers
• CPC Class Codes: C09J 2400/283 : in the substrate
• CPC Class Codes: C09J 2471/006 : in the substrate
• CPC Class Codes: C09J 2477/00 : Presence of polyamide
• CPC Class Codes: C09J 5/00 : Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
• CPC Class Codes: C09J 7/21 : Paper; Textile fabrics
• CPC Class Codes: C09J 7/25 : based on macromolecular compounds obtained otherwise than by reactions involving only carbon-to-carbon unsaturated bonds
• CPC Class Codes: C09J 7/30 : characterised by the adhesive composition
• CPC Class Codes: E04B 1/942 : slab-shaped
• CPC Class Codes: E04C 2/02 : characterised by specified materials translucent E04C2/54
• CPC Class Codes: Y02T 50/40 : Weight reduction
• CPC Class Codes: Y10T 428/24331 : including nonapertured component
• CPC Class Codes: Y10T 428/24942 : including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/2495 : Thickness [relative or absolute]
• CPC Class Codes: Y10T 428/24975 : No layer or component greater than 5 mils thick
• CPC Class Codes: Y10T 428/273 : of coating

Abstract

A multilayer laminate comprising in order, a polymeric film layer capable of withstanding a temperature of at least 200 C for at least 10 min, an adhesive layer having an areal weight of from 2 to 40 gsm capable of activation at a temperature of from 75 to 200 degrees C. and an inorganic refractory layer.

Claims

1. A multilayer laminate for use as a flame barrier layer for an aircraft comprising in order (i) a polymeric film layer capable of withstanding a temperature of at least 200 C for at least 10 min,

(ii) an adhesive layer having an areal weight of from 2 to 40 gsm capable of activation at a temperature of from 75 to 200 degrees C., and

(iii) an inorganic refractory layer;

wherein the inorganic refractory layer of (iii) comprises platelets in an amount of 100% by weight with a dry areal weight of 15 to 50 gsm and a residual moisture content of no greater than 10 percent by weight.

2. The laminate of claim 1 wherein the inorganic refractory layer comprises vermiculite.

3. The laminate of claim 1 wherein the inorganic refractory layer is perforated.

4. The laminate of claim 3 wherein the adhesive bond between the inorganic refractory layer and the polymeric film is at least 1.0 lb/in.

5. The laminate of claim 1 wherein the polymeric film layer is a fluoropolymer, polyimide, polyetheretherketone, or polyetherketoneketone.

6. The laminate of claim 1 wherein the polymeric film layer is metalized on at least one surface.

7. The laminate of claim 1 wherein the adhesive layer contains up to 40 weight percent of a flame retardant ingredient.

8. The laminate of claim 1 wherein the adhesive bond between the inorganic refractory layer and the polymeric film is at least 0.25 lb/in.

9. The laminate of claim 8 wherein the adhesive bond between the inorganic refractory layer and the polymeric film is at least 0.8 lb/in.

10. The laminate of claim 1 wherein the inorganic refractory layer has a dry areal weight of from 20 to 35 gsm.

11. The laminate of claim 1 wherein the inorganic refractory layer has a moisture content of no greater than 3%.