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Flame resistant fibrous insulation and methods of making the same

a technology of fibrous insulation and thermal insulation materials, which is applied in the direction of heat-proofing, fire-proofing, ceilings, etc., can solve the problems of fibrous insulation products that can melt and burn, and achieve the effect of improving their flame resistan

Inactive Publication Date: 2005-10-27
CERTAINTEED CORP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0008] The phosphate-containing compound and the refractory mineral filler can be simply interspersed within the fibers of the insulation products or incorporated into a binding composition that comprises an adhesive (e.g., a polymer commonly used for binding fiberglass in insulation products) for binding the fibrous mineral. Alternativ

Problems solved by technology

Previous fibrous insulation products can melt, burn, or otherwise permit passage of flame therethrough when exposed to fire.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

[0051] The effect of particulate alumina and aluminum sulfate on flame resistance of approximately one-inch-think slices of R30 fiberglass insulation was assessed. The effect of particle size was assessed using alumina preparations having different average particle sizes—either one micron (“1 micron pA” in Table 1) or two microns (“2 micron pA” in Table 1). The effect of particle loading on flame resistance of the insulation was assessed by varying the particle content of the insulation.

[0052] The particulate refractory mineral filler was prepared by suspending either 7.3 or 14.6 grams of either aluminum sulfate or alumina (2 micrometer particle size Hydral H716 alumina or 1 micrometer particle size Hydral H710 alumina) in a solution consisting of 525 milliliters of water and 225 milliliters of isopropyl alcohol. For each sample, an approximately ten-inch-thick piece of R30 fiberglass insulation was divided into one-inch-thick layers, and individual layers were cut into twelve-inch...

example 2

[0056] The effect of particulate aluminum sulfate (“AS” in Table 2) combined with particulate ammonium phosphate (“AP” in Table 2) on flame resistance of approximately one inch-think slices of R13 fiberglass insulation was assessed. The effect of particle loading on flame resistance of the insulation was assessed by varying the particle content of the insulation.

[0057] The particulate refractory mineral filler was prepared by suspending either 4.5 or 9.0 grams each of aluminum sulfate and ammonium phosphate in a solution consisting of 525 milliliters of water and 225 milliliters of isopropyl alcohol. For each sample, an approximately twelve inch square of one-inch-thick insulation was cut into six-inch square quarters, and 240 milliliters of the suspension was poured onto the insulation to evenly distribute the particles in the insulation. The particulate content of each sample was determined by comparing the dry weight of the sample after drying at room temperature with the pre-tr...

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Abstract

The invention relates to fibrous insulation products that exhibit improved flame resistance, relative to previously known products. The insulation product has a fibrous mineral matrix, into which is incorporated a phosphate-containing compound (e.g., an inorganic phosphate salt) and a refractory mineral filler (e.g., alumina or aluminum sulfate). The product exhibits flame resistance superior to the fibrous mineral matrix alone.

Description

BACKGROUND OF THE INVENTION [0001] The invention relates generally to the field of fibrous mineral-based thermal insulating materials. [0002] Fibrous insulation products are widely used in the building construction industries and as components of other manufactured goods such as automobiles, aircraft, and soundproofing products. Various naturally-occurring and synthetic fibrous minerals are used to make fibrous insulation products, including fibers synthesized from glass, rock, slag, or basalt. Fibrous insulation products can be used in the form of loose bulk fibers. Commonly, mineral fibers are bound to one another using any of a variety of known adhesives. Bound mineral fibers are also commonly attached to supports or backings, such as paper and / or metal foils, to facilitate their handling and installation. [0003] Fibrous insulation products are often used in environments (e.g., residences, office buildings, manufacturing facilities, and vehicles) in which fire is a hazard. Previo...

Claims

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Application Information

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IPC IPC(8): D04H1/00D04H13/00E04B1/76E04B1/94
CPCC04B30/02C04B2111/28D04H13/008E04B1/7658E04B1/941E04B9/045C04B14/30C04B14/42C04B22/16D04H1/4218D04H1/4226
Inventor TOAS, MURRAY S.YANG, ALAINDAVIS, KIM
Owner CERTAINTEED CORP
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