U.S. patent application number 10/626425 was filed with the patent office on 2004-07-08 for burn through and flame propagation resistant layer or covering.
This patent application is currently assigned to Johns Manville International, Inc.. Invention is credited to Fay, Ralph Michael, Wulliman, Rebecca S..
Application Number | 20040132364 10/626425 |
Document ID | / |
Family ID | 24383418 |
Filed Date | 2004-07-08 |
United States Patent
Application |
20040132364 |
Kind Code |
A1 |
Wulliman, Rebecca S. ; et
al. |
July 8, 2004 |
Burn through and flame propagation resistant layer or covering
Abstract
A burn through and flame propagation resistant system, includes
a sheet of burn through and flame propagation resistant paper made
of aramid fibers, mica flakes, and aramid fibrid binder; and one or
more sheets of polymeric film, preferably, flame propagation
resistant polymeric film, bonded to at least one major surface of
the sheet of burn through and flame propagation resistant paper to
form a laminated sheet. Preferably, for many applications, the
system is also water vapor transmission resistant with the sheet or
sheets of polymeric film or a coating providing the water vapor
transmission resistance. The burn through and flame propagation
resistant paper and/or polymeric film(s) may have major surface(s)
coated with a heat sealable adhesive, e.g. for securing the
laminated sheet to itself or another laminated sheet to form a bag
or envelope for encapsulating insulation. The laminated sheet may
be used as a covering or bag that encapsulates insulation material
or as a layer overlaying, intermediate or underlaying one or more
layers of insulation material. As an alternative to the laminated
sheet, the system may include a sheet of burn through and flame
propagation resistant paper which is treated with a heat and/or
ultrasonically sealable, moisture and flame propagation resistant
polyvinylfluoride water based emulsion.
Inventors: |
Wulliman, Rebecca S.;
(Englewood, CO) ; Fay, Ralph Michael; (Lakewood,
CO) |
Correspondence
Address: |
Johns Manville Corporation
Intellectual Property (R21D)
10100 West Ute Avenue
Littleton
CO
80127
US
|
Assignee: |
Johns Manville International,
Inc.
|
Family ID: |
24383418 |
Appl. No.: |
10/626425 |
Filed: |
July 24, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10626425 |
Jul 24, 2003 |
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09595483 |
Jun 16, 2000 |
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6627561 |
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Current U.S.
Class: |
442/38 ; 442/149;
442/150; 442/40; 442/79; 442/82 |
Current CPC
Class: |
Y10T 442/699 20150401;
Y10T 442/2738 20150401; F01N 3/2864 20130101; B32B 27/10 20130101;
Y10T 428/3154 20150401; Y10T 442/2746 20150401; F01N 3/2857
20130101; Y10T 442/164 20150401; D21H 13/26 20130101; Y10T 442/619
20150401; Y10T 442/2189 20150401; Y10T 442/677 20150401; Y10T
442/696 20150401; Y10T 442/2213 20150401; Y10T 442/167 20150401;
Y10S 428/92 20130101; D21H 13/44 20130101; Y10T 428/2817 20150115;
Y10T 442/2221 20150401; Y10T 442/2902 20150401; Y10T 428/24331
20150115; A62C 8/06 20130101; Y10T 442/674 20150401; Y10T 442/2164
20150401; Y10T 442/10 20150401 |
Class at
Publication: |
442/038 ;
442/079; 442/082; 442/149; 442/150; 442/040 |
International
Class: |
B32B 027/12; B32B
027/04; B32B 027/32; B32B 005/02 |
Claims
What is claimed is:
1. A burn through and flame propagation resistant laminate,
comprising: a sheet of burn through and flame propagation resistant
paper comprising: aramid fibers, mica flakes, and aramid fibrid
binder; and a first sheet of polymeric film having a first major
surface bonded to a first major surface of the sheet of burn
through and flame propagation resistant paper and forming, with the
sheet of burn through and flame propagation resistant paper, a
laminated sheet.
2. The burn through and flame propagation resistant laminate
according to claim 1, wherein: the sheet of burn through and flame
propagation resistant paper has from about 30% to about 50% by
weight mica.
3. The burn through and flame propagation resistant laminate
according to claim 1, wherein: the sheet of burn through and flame
propagation resistant paper is treated with a fluorocarbon to make
the sheet of burn through and flame propagation resistant paper
more water repellant.
4. The burn through and flame propagation resistant laminate
according to claim 1, wherein: the first sheet of polymeric film is
a water vapor transmission resistant film having a water vapor
permeability of 4.0 perms or less.
5. The burn through and flame propagation resistant laminate
according to claim 1, wherein: the first sheet of polymeric film is
a water vapor transmission and flame propagation resistant
polymeric film having a water vapor permeability of 4.0 perms or
less.
6. The burn through and flame propagation resistant laminate
according to claim 1, wherein: the first sheet of polymeric film is
a water vapor transmission and flame propagation resistant
polymeric film, having a water vapor permeability of 4.0 perms or
less, selected from a group consisting of polyvinylfluoride and
polyimide films.
7. The burn through and flame propagation resistant laminate
according to claim 1, wherein: a second major surface of the first
sheet of polymeric film is coated with a heat sealable
adhesive.
8. The burn through and flame propagation resistant laminate
according to claim 1, wherein: a second major surface of the sheet
of burn through and flame propagation resistant paper is coated
with a heat sealable adhesive.
9. The burn through and flame propagation resistant laminate
according to claim 1, wherein: the laminated sheet is reinforced
with scrim to increase the puncture and tear resistance of the
laminated sheet.
10. The burn through and flame propagation resistant laminate
according to claim 1, wherein: the first sheet of polymeric film is
a water vapor transmission and flame propagation resistant
polymeric film having a water vapor permeability of 4.0 perms or
less; and a second major surface of the first sheet of polymeric
film is coated with a heat sealable adhesive.
11. The burn through and flame propagation resistant laminate
according to claim 10, including: a sheet of scrim bonded by the
coating of heat sealable adhesive to the polymeric film to increase
the puncture and tear resistance of the laminated sheet.
12. The burn through and flame propagation resistant laminate
according to claim 1, wherein: the first sheet of polymeric film is
a water vapor transmission and flame propagation resistant
polymeric film having a water vapor permeability of 4.0 perms or
less; and a second major surface of the sheet of burn through and
flame propagation resistant paper is coated with a heat sealable
adhesive.
13. The burn through and flame propagation resistant laminate
according to claim 12, including: a sheet of scrim bonded by the
coating of heat sealable adhesive to the burn through and flame
propagation resistant paper of the laminated sheet to increase the
puncture and tear resistance of the laminated sheet.
14. The burn through and flame propagation resistant laminate
according to claim 1, including: a second sheet of polymeric film
having a first major surface bonded to a second major surface of
the sheet of burn through and flame propagation resistant paper;
and at least one of the first and second sheets of polymeric film
being flame propagation and water vapor transmission resistant and
having a water vapor permeability of 4.0 perms or less.
15. The burn through and flame propagation resistant laminate
according to claim 14, wherein: the sheet of burn through and flame
propagation resistant paper has from about 30% to about 50% by
weight mica.
16. The burn through and flame propagation resistant laminate
according to claim 14, wherein: the sheet of burn through and flame
propagation resistant paper is treated with a fluorocarbon to make
the sheet of burn through and flame propagation resistant paper
more water repellant.
17. The burn through and flame propagation resistant laminate
according to claim 14, wherein: a second major surface of the first
sheet polymeric film is coated with a heat sealable adhesive.
18. The burn through and flame propagation resistant laminate
according to claim 14, wherein: second major surfaces of the first
and second sheets of polymeric film are coated with a heat sealable
adhesive.
19. The burn through and flame propagation resistant laminate
according to claim 14, wherein: the laminated sheet is reinforced
with scrim to increase the puncture and tear resistance of the
laminated sheet.
20. A burn through and flame propagation resistant insulation
system comprising: a burn through and flame propagation resistant
laminated sheet; the laminated sheet including a sheet of burn
through and flame propagation resistant paper comprising: aramid
fibers, mica flakes, and aramid fibrid binder; and a first sheet of
polymeric film having a first major surface bonded to a first major
surface of the sheet of burn through and flame propagation
resistant paper; a layer of lightweight, flexible, thermal and
acoustical insulation material; the layer of insulation material
having first and second major surfaces; and the laminated sheet
overlaying a major surface of the layer of insulation material.
21. The burn through and flame propagation resistant insulation
system according to claim 20, wherein: the layer of lightweight,
flexible, thermal and acoustical insulation material is a glass
fiber insulation material.
22. The burn through and flame propagation resistant insulation
system according to claim 20, wherein: the layer of lightweight,
flexible, thermal and acoustical insulation material is a polyimide
foam insulation material.
23. The burn through and flame propagation resistant insulation
system according to claim 20, wherein: the sheet of burn through
and flame propagation resistant paper of the laminated sheet has
from about 30% to about 50% by weight mica.
24. The burn through and flame propagation resistant insulation
system according to claim 20, wherein: the sheet of burn through
and flame propagation resistant paper of the laminated sheet is
treated with a fluorocarbon to make the sheet of burn through and
flame propagation resistant paper more water repellant.
25. The burn through and flame propagation resistant insulation
system according to claim 20, wherein: the first sheet of polymeric
film of the laminated sheet is a water vapor transmission resistant
film having a water vapor permeability of 4.0 perms or less.
26. The burn through and flame propagation resistant insulation
system according to claim 20, wherein: the first sheet of polymeric
film of the laminated sheet is a water vapor transmission and flame
propagation resistant polymeric film having a water vapor
permeability of 4.0 perms or less.
27. The burn through and flame propagation resistant insulation
system according to claim 20, wherein: the first sheet of polymeric
film of the laminated sheet is a water vapor transmission and flame
propagation resistant polymeric film, having a water vapor
permeability of 4.0 perms or less, selected from a group consisting
of polyvinylfluoride and polyimide films.
28. The burn through and flame propagation resistant insulation
system according to claim 20, wherein: a second major surface of
the first sheet of polymeric film of the laminated sheet is coated
with a heat sealable adhesive.
29. The burn through and flame propagation resistant insulation
system according to claim 20, wherein: a second major surface of
the sheet of burn through and flame propagation resistant paper of
the laminated sheet is coated with a heat sealable adhesive.
30. The burn through and flame propagation resistant insulation
system according to claim 20, wherein: the laminated sheet includes
a reinforcing scrim to increase the puncture and tear resistance of
the laminated sheet.
31. The burn through and flame propagation resistant insulation
system according to claim 20, wherein: the first sheet of polymeric
film of the laminated sheet is a water vapor transmission and flame
propagation resistant polymeric film having a water vapor
permeability of 4.0 perms or less; and a second major surface of
the first sheet of polymeric film of the laminated sheet is coated
with a heat sealable adhesive.
32. The burn through and flame propagation resistant insulation
system according to claim 31, including: a sheet of scrim bonded by
the coating of heat sealable adhesive to the polymeric film of the
laminated sheet to increase the puncture and tear resistance of the
laminated sheet.
33. The burn through and flame propagation resistant insulation
system according to claim 20, wherein: the first sheet of polymeric
film of the laminated sheet is a water vapor transmission and flame
propagation resistant polymeric film having a water vapor
permeability of 4.0 perms or less; and a second major surface of
the sheet of burn through and flame propagation resistant paper of
the laminated sheet is coated with a heat sealable adhesive.
34. The burn through and flame propagation resistant insulation
system according to claim 33, including: a sheet of scrim bonded by
the coating of heat sealable adhesive to the burn through and flame
propagation resistant paper of the laminated sheet to increase the
puncture and tear resistance of the laminated sheet.
35. The burn through and flame propagation resistant insulation
system according to claim 20, wherein: the laminated sheet includes
a second sheet of polymeric film having a first major surface
bonded to a second major surface of the sheet of burn through and
flame propagation resistant paper; and at least one of the first
and second sheets of polymeric film are flame propagation and water
vapor transmission resistant and having a water vapor permeability
of 4.0 perms or less.
36. The burn through and flame propagation resistant insulation
system according to claim 35, wherein: the sheet of burn through
and flame propagation resistant paper of the laminated sheet has
from about 30% to about 50% by weight mica.
37. The burn through and flame propagation resistant insulation
system according to claim 35, wherein: the sheet of burn through
and flame propagation resistant paper of the laminated sheet is
treated with a fluorocarbon to make the sheet of burn through and
flame propagation resistant paper more water repellant.
38. The burn through and flame propagation resistant insulation
system according to claim 35, wherein: a second major surface of
the first sheet polymeric film is coated with a heat sealable
adhesive.
39. The burn through and flame propagation resistant insulation
system according to claim 35, wherein: second major surfaces of the
first and second sheets of polymeric film of the laminated sheet
are coated with a heat sealable adhesive.
40. The burn through and flame propagation resistant insulation
system according to claim 35, wherein: the laminated sheet includes
a reinforcing scrim to increase the puncture and tear resistance of
the laminated sheet.
41. The burn through and flame propagation resistant insulation
system according to claim 20, wherein: the system is located within
a cavity of an aircraft fuselage; the cavity having an outboard
side formed by an outer metal skin and framework and an inboard
side formed by cabin trim panels; and the laminated sheet is
located intermediate the insulation layer of the insulation system
and the outboard side of the cavity.
42. The burn through and flame propagation resistant insulation
system according to claim 41, wherein: the insulation layer
comprises a plurality of encapsulated insulation assemblies.
43. The burn through and flame propagation resistant insulation
system according to claim 20, wherein: the system is located within
a cavity of an aircraft fuselage; the cavity having an outboard
side formed by an outer metal skin and framework and an inboard
side formed by cabin trim panels; and the laminated sheet is
located intermediate the insulation layer of the insulation system
and the inboard side of the cavity.
44. The burn through and flame propagation resistant insulation
system according to claim 43, wherein: the insulation layer
comprises a plurality of encapsulated insulation assemblies.
45. A burn through and flame propagation resistant insulation
system comprising: an envelope formed of a burn through and flame
propagation resistant laminated sheet; the laminated sheet
including a sheet of burn through and flame propagation resistant
paper comprising: aramid fibers, mica flakes, and aramid fibrid
binder; and a first sheet of polymeric film having a first major
surface bonded to a first major surface of the sheet of burn
through and flame propagation resistant paper; a layer of
lightweight, flexible, thermal and acoustical insulation material
contained within the envelope.
46. The burn through and flame propagation resistant insulation
system according to claim 45, wherein: the layer of lightweight,
flexible, thermal and acoustical insulation material is a glass
fiber insulation material.
47. The burn through and flame propagation resistant insulation
system according to claim 45, wherein: the layer of lightweight,
flexible, thermal and acoustical insulation material is a polyimide
foam insulation material.
48. The burn through and flame propagation resistant insulation
system according to claim 45, wherein: the sheet of burn through
and flame propagation resistant paper of the laminated sheet has
from about 30% to about 50% by weight mica.
49. The burn through and flame propagation resistant insulation
system according to claim 45, wherein: the sheet of burn through
and flame propagation resistant paper of the laminated sheet is
treated with a fluorocarbon to make the sheet of burn through and
flame propagation resistant paper more water repellant.
50. The burn through and flame propagation resistant insulation
system according to claim 45, wherein: the first sheet of polymeric
film of the laminated sheet is a water vapor transmission resistant
film having a water vapor permeability of 4.0 perms or less.
51. The burn through and flame propagation resistant insulation
system according to claim 45, wherein: the first sheet of polymeric
film of the laminated sheet is a water vapor transmission and flame
propagation resistant polymeric film having a water vapor
permeability of 4.0 perms or less; and the first sheet of polymeric
film forms an outer surface of the envelope to restrict the
transmission of water vapor into the burn through and flame
propagation resistant paper and the insulation layer.
52. The burn through and flame propagation resistant insulation
system according to claim 45, wherein: the first sheet of polymeric
film of the laminated sheet is a water vapor transmission and flame
propagation resistant polymeric film, having a water vapor
permeability of 4.0 perms or less, selected from a group consisting
of polyvinylfluoride and polyimide films; and the first sheet of
polymeric film forms an outer surface of the envelope to restrict
the transmission of water vapor into the burn through and flame
propagation resistant paper and the insulation layer.
53. The burn through and flame propagation resistant insulation
system according to claim 45, wherein: a second major surface of
the first sheet of polymeric film of the laminated sheet is coated
with a heat sealable adhesive.
54. The burn through and flame propagation resistant insulation
system according to claim 45, wherein: a second major surface of
the sheet of burn through and flame propagation resistant paper of
the laminated sheet is coated with a heat sealable adhesive.
55. The burn through and flame propagation resistant insulation
system according to claim 45, wherein: the laminated sheet includes
a reinforcing scrim to increase the puncture and tear resistance of
the laminated sheet.
56. The burn through and flame propagation resistant insulation
system according to claim 45, wherein: the first sheet of polymeric
film of the laminated sheet is a water vapor transmission and flame
propagation resistant polymeric film having a water vapor
permeability of 4.0 perms or less; and a second major surface of
the first sheet of polymeric film of the laminated sheet is coated
with a heat sealable adhesive.
57. The burn through and flame propagation resistant insulation
system according to claim 56, including: a sheet of scrim bonded by
the coating of heat sealable adhesive to the polymeric film of the
laminated sheet to increase the puncture and tear resistance of the
laminated sheet.
58. The burn through and flame propagation resistant insulation
system according to claim 45, wherein: the first sheet of polymeric
film of the laminated sheet is a water vapor transmission and flame
propagation resistant polymeric film having a water vapor
permeability of 4.0 perms or less; and a second major surface of
the sheet of burn through and flame propagation resistant paper of
the laminated sheet is coated with a heat sealable adhesive.
59. The burn through and flame propagation resistant insulation
system according to claim 58, including: a sheet of scrim bonded by
the coating of heat sealable adhesive to the burn through and flame
propagation resistant paper of the laminated sheet to increase the
puncture and tear resistance of the laminated sheet.
60. The burn through and flame propagation resistant insulation
system according to claim 45, wherein: the laminated sheet includes
a second sheet of polymeric film having a first major surface
bonded to a second major surface of the sheet of burn through and
flame propagation resistant paper; and at least one of the first
and second sheets of polymeric film are flame propagation and water
vapor transmission resistant and having a water vapor permeability
of 4.0 perms or less.
61. The burn through and flame propagation resistant insulation
system according to claim 60, wherein: the sheet of burn through
and flame propagation resistant paper of the laminated sheet has
from about 30% to about 50% by weight mica.
62. The burn through and flame propagation resistant insulation
system according to claim 60, wherein: the sheet of burn through
and flame propagation resistant paper of the laminated sheet is
treated with a fluorocarbon to make the sheet of burn through and
flame propagation resistant paper more water repellant.
63. The burn through and flame propagation resistant insulation
system according to claim 60, wherein: a second major surface of
the first sheet polymeric film is coated with a heat sealable
adhesive.
64. The burn through and flame propagation resistant insulation
system according to claim 60, wherein: second major surfaces of the
first and second sheets of polymeric film of the laminated sheet
are coated with a heat sealable adhesive.
65. The burn through and flame propagation resistant insulation
system according to claim 60, wherein: the laminated sheet includes
a reinforcing scrim to increase the puncture and tear resistance of
the laminated sheet.
66. The burn through and flame propagation resistant insulation
system according to claim 45, wherein: the system is located within
a cavity of an aircraft fuselage; the cavity having an outboard
side formed by an outer metal skin and framework and an inboard
side formed by cabin trim panels.
67. A burn through, flame propagation and water vapor transmission
resistant sheet, comprising: a sheet of burn through and flame
propagation resistant paper having first and second major surfaces
and comprising: aramid fibers, mica flakes, and aramid fibrid
binder; the sheet of burn through and flame propagation resistant
paper having the first major surface treated with a heat sealable,
moisture and flame propagation resistant polyvinylfluoride water
based emulsion coating and having a water vapor permeability of 4.0
perms or less.
68. The burn through, flame propagation and water vapor
transmission resistant sheet according to claim 67, wherein: the
sheet of burn through and flame propagation resistant paper has
from about 30% to about 50% by weight mica.
69. The burn through, flame propagation and water vapor
transmission resistant sheet according to claim 67, wherein: the
polyvinylfluoride coating, by dry weight, is between 20 and 100
g/m.sup.2.
70. The burn through, flame propagation and water vapor
transmission resistant sheet according to claim 67, including: a
sheet of reinforcing scrim bonded to one of the major surfaces of
the sheet of burn through and flame propagation resistant paper to
increase the puncture and tear resistance of the burn through,
flame propagation and water vapor transmission resistant sheet.
71. The burn through, flame propagation and water vapor
transmission resistant sheet according to claim 67, including: a
sheet of reinforcing scrim bonded by the heat sealable
polyvinylfluoride coating to the first major surface of the sheet
of burn through and flame propagation resistant paper to increase
the puncture and tear resistance of the burn through, flame
propagation and water vapor transmission resistant sheet.
72. The burn through, flame propagation and water vapor
transmission resistant sheet according to claim 67, wherein: the
sheet of burn through and flame propagation resistant paper having
a second major surface treated with a heat sealable, moisture and
flame propagation resistant polyvinylfluoride water based emulsion
coating.
73. A burn through, flame propagation and water vapor transmission
resistant insulation system comprising: a burn through, flame
propagation and water vapor transmission resistant sheet comprising
a sheet of burn through and flame propagation resistant paper
having first and second major surfaces and comprising: aramid
fibers, mica flakes, and aramid fibrid binder; the sheet of burn
through and flame propagation resistant paper having the first
major surface treated with a heat sealable, moisture and flame
propagation resistant polyvinylfluoride water based emulsion
coating and having a water vapor permeability of 4.0 perms or less;
a layer of lightweight, flexible, thermal and acoustical insulation
material; the layer of insulation material having first and second
major surfaces; and the burn through, flame propagation and water
vapor transmission resistant sheet overlaying a major surface of
the layer of insulation material.
74. The burn through, flame propagation and water vapor
transmission resistant insulation system according to claim 73,
wherein: the sheet of burn through and flame propagation resistant
paper has from about 30% to about 50% by weight mica.
75. The burn through, flame propagation and water vapor
transmission resistant insulation system according to claim 73,
wherein: the heat sealable polyvinylfluoride coating, by dry
weight, is between 20 and 100 g/m.sup.2.
76. The burn through, flame propagation and water vapor
transmission resistant insulation system according to claim 73,
including: a sheet of reinforcing scrim bonded to one of the major
surfaces of the sheet of burn through and flame propagation
resistant paper to increase the puncture and tear resistance of the
burn through, flame propagation and water vapor transmission
resistant sheet.
77. The burn through, flame propagation and water vapor
transmission resistant insulation system according to claim 73,
including: a sheet of reinforcing scrim bonded by the heat sealable
polyvinylfluoride coating to the first major surface of the sheet
of burn through and flame propagation resistant paper to increase
the puncture and tear resistance of the burn through, flame
propagation and water vapor transmission resistant sheet.
78. The burn through, flame propagation and water vapor
transmission resistant sheet according to claim 73, wherein: the
sheet of burn through and flame propagation resistant paper has a
second major surface treated with a heat sealable, moisture and
flame propagation resistant polyvinylfluoride water based emulsion
coating.
79. The burn through, flame propagation and water vapor
transmission resistant insulation system according to claim 73,
wherein: the layer of lightweight, flexible, thermal and acoustical
insulation material is a glass fiber insulation material.
80. The burn through, flame propagation and water vapor
transmission resistant insulation system according to claim 73,
wherein: the layer of lightweight, flexible, thermal and acoustical
insulation material is a polyimide foam insulation material.
81. The burn through, flame propagation and water vapor
transmission resistant insulation system according to claim 73,
wherein: the system is located within a cavity of an aircraft
fuselage; the cavity having an outboard side formed by an outer
metal skin and framework and an inboard side formed by cabin trim
panels; and the burn through, flame propagation and water vapor
transmission resistant sheet is located intermediate the insulation
layer of the insulation system and the outboard side of the
cavity.
82. The burn through, flame propagation and water vapor
transmission resistant insulation system according to claim 81,
wherein: the insulation layer comprises a plurality of encapsulated
insulation assemblies.
83. The burn through, flame propagation and water vapor
transmission resistant insulation system according to claim 73,
wherein: the system is located within a cavity of an aircraft
fuselage; the cavity having an outboard side formed by an outer
metal skin and framework and an inboard side formed by cabin trim
panels; and the burn through, flame propagation and water vapor
transmission resistant sheet is located intermediate the insulation
layer of the insulation system and the inboard side of the
cavity.
84. The burn through, flame propagation and water vapor
transmission resistant insulation system according to claim 83,
wherein: the insulation layer comprises a plurality of encapsulated
insulation assemblies.
85. A burn through and flame propagation resistant insulation
system comprising: an envelope formed of a burn through, flame
propagation and water vapor transmission resistant sheet; the burn
through, flame propagation and water vapor transmission resistant
sheet comprising a sheet of burn through and flame propagation
resistant paper having first and second major surfaces and
comprising: aramid fibers, mica flakes, and aramid fibrid binder;
the sheet of burn through and flame propagation resistant paper
having the first major surface treated with a heat sealable,
moisture and flame propagation resistant polyvinylfluoride water
based emulsion coating and having a water vapor permeability of 4.0
perms or less; a layer of lightweight, flexible, thermal and
acoustical insulation material contained within the envelope.
86. The burn through, flame propagation and water vapor
transmission resistant insulation system according to claim 85,
wherein: the sheet of burn through and flame propagation resistant
paper has from about 30% to about 50% by weight mica.
87. The burn through, flame propagation and water vapor
transmission resistant insulation system according to claim 85,
wherein: the heat sealable polyvinylfluoride coating, by dry
weight, is between 20 and 100 g/m.sup.2.
88. The burn through, flame propagation and water vapor
transmission resistant insulation system according to claim 85,
including: a sheet of reinforcing scrim bonded to one of the major
surfaces of the sheet of burn through and flame propagation
resistant paper to increase the puncture and tear resistance of the
burn through, flame propagation and water vapor transmission
resistant sheet.
89. The burn through, flame propagation and water vapor
transmission resistant insulation system according to claim 85,
including: a sheet of reinforcing scrim bonded by the heat sealable
polyvinylfluoride coating to the first major surface of the sheet
of burn through and flame propagation resistant paper to increase
the puncture and tear resistance of the burn through, flame
propagation and water vapor transmission resistant sheet.
90. The burn through, flame propagation and water vapor
transmission resistant sheet according to claim 85, wherein: the
sheet of burn through and flame propagation resistant paper has a
second major surface treated with a heat sealable, moisture and
flame propagation resistant polyvinylfluoride water based emulsion
coating.
91. The burn through, flame propagation and water vapor
transmission resistant insulation system according to claim 85,
wherein: the layer of lightweight, flexible, thermal and acoustical
insulation material is a glass fiber insulation material.
92. The burn through, flame propagation and water vapor
transmission resistant insulation system according to claim 85,
wherein: the layer of lightweight, flexible, thermal and acoustical
insulation material is a polyimide foam insulation material.
93. The burn through, flame propagation and water vapor
transmission resistant insulation system according to claim 85,
wherein: the system is located within a cavity of an aircraft
fuselage; the cavity having an outboard side formed by an outer
metal skin and framework and an inboard side formed by cabin trim
panels.
94. The burn through, flame propagation and water vapor
transmission resistant insulation system according to claim 85,
wherein: the heat sealable polyvinylfluoride coating forms an outer
surface of the envelope to restrict the transmission of water vapor
into the burn through and flame propagation resistant paper and the
insulation layer.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates to a burn through and flame
propagation resistant layer or covering for use in thermal and
acoustical insulation systems, such as, but not limited to, those
used in commercial aircraft. Preferably, for many applications such
as commercial aircraft, the burn through and flame propagation
resistant layer is also water vapor transmission resistant. The
invention can be used as a layer or covering, e.g. interleaved
between, laid over, or laid behind layers of thermal and acoustical
insulation material or as a covering or bag for partially or
totally encapsulating one or more layers of thermal and acoustical
insulation material. While the burn through and flame propagation
resistant layer or covering of the present invention is
particularly well suited for aircraft applications, especially when
the layer or covering is also water vapor transmission resistant,
the burn through and flame propagation layer or covering may also
be used for other applications where layers or coverings having
these properties are needed or desirable.
[0002] The Notice of Proposed Rule-making expected to be issued by
the Federal Aviation Administration (FAA) in the near future will
require thermal and acoustical insulation blanket systems in
commercial aircraft to provide improved burn through protection and
flame propagation resistance. These systems typically include
thermal and acoustical insulation blankets encapsulated within a
film covering or bag. As the thermal and acoustical insulation
systems are currently constructed, the burn through regulations
primarily affect the contents of the insulation systems bags and
the flame propagation resistance regulations primarily affect the
film coverings used to fabricate the bags. Previous development
work by a number of manufacturers has addressed the burn through
resistance of the insulation within the bags or the flame
propagation resistance of the film coverings used to fabricate the
bags housing the insulation. However, no current system has solved
both problems in the same product while providing the properties
and low costs necessary for widespread commercial acceptance. Some
of the systems currently being proposed are outlined in the
following paragraphs.
[0003] With regard to burn through resistance one proposed system
would utilize one or more layers of a nonwoven mat, made of fibers
commercially available from The 3M Company of St. Paul, Minn. under
the trade designation "NEXTEL" as a fire barrier in the insulation
blanket. The mat weighs 65 g/m.sup.2 and costs $15.00/m.sup.2 or
more. Flame propagation issues still have to be addressed in
connection with the film covering material.
[0004] With regard to flame propagation resistance, one proposed
system would use a reinforced metallized polyvinylfluoride film
covering manufactured by Facile Holdings, Inc. of Paterson, N.J.,
under the trade designations "INSULFAB 330.RTM. or INSULFAB
331.RTM.". The reinforced metallized polyvinylfluoride film
provides flame propagation resistance to the system but weighs 44
g/m.sup.2 and costs about $9.00/m.sup.2 compared to the reinforced
polyester film covering currently used to fabricate the bag which
weighs 25 g/m.sup.2 and costs about $2.70/m.sup.2.
[0005] Another proposal for flame propagation resistance is a
system which would use reinforced polyimide film covering material
manufactured by Orcon Corporation under the trade designation
"KN-80.RTM.". The reinforced polyimide film covering material
provides flame propagation resistance to the system but weighs 50
g/m.sup.2 and costs about $13.00/m.sup.2 compared to the reinforced
polyester film covering currently used to fabricate the bag which
weighs 25 g/m.sup.2 and costs about $2.70/m.sup.2. Alone, this
reinforced polyimide film covering does not provide significant
burn through resistance.
SUMMARY OF THE INVENTION
[0006] The preferred burn through and flame propagation resistant
layer or covering of the present invention, which is also water
vapor transmission resistant, provides a solution, in a single
light weight product, to both the burn through and the flame
propagation requirements for light weight, thermal and acoustical
insulation systems (such as those to be used in commercial
aircraft) while also providing the water vapor transmission
resistance required by such insulation systems. Furthermore, the
burn through, flame propagation and water vapor transmission
resistant layer or covering of the present invention can be easily
incorporated into such insulation systems without the need to
redesign the individual components of the system, e.g. by making
the bag that contains or houses the insulation of the system from
the covering of the present invention. Typically, the individual
thermal and acoustical insulation components used to insulate
aircraft fuselages are specifically designed at considerable cost
to very close tolerances (e.g. length, width, thickness, and
configuration) to precisely fit each specific portion of the
fuselage. Thus, the ability to incorporate the burn through, flame
propagation and, preferably, water vapor transmission resistant
layer or covering of the present invention into such insulation
systems without the need to redesign the individual components of
the system is a valuable characteristic of the present
invention.
[0007] One preferred embodiment of the burn through, flame
propagation and water vapor transmission resistant system of the
present invention includes a layer or covering which includes a
sheet of burn through and flame propagation resistant paper made of
aramid fibers, mica flakes, and aramid fibrid binder; and a sheet
of water vapor transmission and flame propagation resistant
polymeric film which has a major surface bonded to one major
surface of the sheet of burn through and flame propagation
resistant paper to form a laminated sheet. The laminated sheet may
include a second sheet of polymeric film bonded to the other major
surface of the burn through and flame propagation resistant
paper.
[0008] The laminated sheet may also have a scrim layer incorporated
into or bonded to the sheet or one of the sheets of the polymeric
film and/or the sheet of burn through and flame propagation
resistant paper to add strength to the laminated sheet, especially
puncture and tear resistance. Furthermore, the sheet of polymeric
film or, when two sheets of polymeric film are used, one of the
sheets or both sheets of polymeric film in the laminated sheet may
have a second major surface coated with a heat or ultrasonically
sealable adhesive (hereinafter "a heat sealable adhesive") for
securing the laminated sheet: to itself or to another laminated
sheet to form a covering, envelope, or bag for containing or
encapsulating an insulation material; to an insulation layer; or to
a structure, such as the skin, framework and/or the trim panels of
an aircraft fuselage.
[0009] When the burn through and flame propagation resistant
laminated sheet is also water vapor transmission resistant and the
laminated sheet is formed into a covering, such as a bag or
envelope, that partially or totally encloses or encapsulates one or
more layers of thermal and acoustical insulation material, such as
lightweight, flexible, glass fiber blankets or sheets of polyimide
foam, the covering, envelope or bag formed from the laminated sheet
serves to inhibit water vapor transmission during normal service
and to inhibit both burn through and flame propagation in the event
of fire. When the burn through and flame propagation resistant
laminated sheet is also water vapor transmission resistant, the
laminated sheet may also be used between layers or as a covering
for one or more layers of lightweight, flexible, thermal and
acoustical insulation material in an insulation system to inhibit
water vapor transmission during normal service and to inhibit both
burn through and flame propagation in the event of fire. For
example, the laminated sheet may be used in a "wallpaper"
application as a covering or layer that is located intermediate
insulation material in fuselage wall cavities and the outer skin of
an aircraft fuselage (as an outboard layer of an insulation system)
or intermediate insulation material in fuselage wall cavities and
the interior aircraft trim panels (as an inboard layer of an
insulation system).
[0010] As an alternative to the laminated sheet described above,
the burn through, flame propagation and, preferably, water vapor
transmission resistant layer or covering of the present invention
may be a sheet of burn through and flame propagation resistant
paper made of aramid fibers, mica flakes, and aramid fibrid binder
which is treated with a heat and/or ultrasonic sealable, moisture
and flame propagation resistant polyvinylfluoride water based
emulsion. As with the burn through, flame propagation and,
preferably, water vapor transmission resistant laminated sheet
described above, the treated sheet of burn through and flame
propagation resistant paper can be used as a covering to contain
thermal and acoustical insulation material (e.g. formed into a bag
or envelope), can be used as a layer located intermediate layers of
insulation material, or as a covering over one or more layers of
such insulation material. The treated sheet of burn through and
flame propagation resistant paper can have a scrim sheet or layer
bonded to a major surface of the paper, preferably, by the heat
sealable, moisture and flame propagation resistant
polyvinylfluoride water based emulsion, to add strength, especially
puncture and tear resistance.
[0011] The burn through, flame propagation and water vapor
transmission resistant layer or covering of the present invention
when used in a thermal and acoustic insulation blanket system for
commercial aircraft passes the FAA medium scale burn through test;
passes the flame propagation test; and preferably, has a water
vapor permeability in perms of 4.0 or less and more preferably, of
2.5 or less. Preferably, the burn through, flame propagation and
water vapor transmission resistant layer or covering of the present
invention meets the material specifications of The Boeing Company
of Seattle, Wash. for burst strength and puncture resistance having
a minimum burst strength of 23 pounds per square inch
(23lb/in.sup.2) (Class 1 Film BMS 8-142) and has a minimum puncture
resistance of 2 pounds. In simulated aircraft fuselage tests,
aircraft thermal and acoustic insulation systems, using bags or
envelopes for containing the insulation blankets made from the burn
through, flame propagation and water vapor transmission resistant
layers or coverings of the present invention, demonstrate heat and
sound transmissions which are equivalent to current systems.
[0012] The burn through test referred to herein is the new Federal
Aviation Administration (FAA) medium scale burn through test as
presently defined (May 22, 2000) by the www.fire.tc.faa.gov web
site (herein referred to as "the FAA medium scale burn through
test"). The FAA medium scale burn through test subjects the hot or
outboard side major surface of a test sample to the flame of an oil
burner that generates a temperature of approximately 1100.degree.
C. The discharge end of the oil burner nozzle is positioned 10
centimeters (10 cm) from and directed toward the hot side major
surface of the sample and generates a pulsating flame front. The
FAA medium scale burn through test measures the cold or inboard
side heat flux at two specific locations on the cold side of the
sample. To pass the FAA medium scale burn through test the sample
must prevent both visible burn through and a cold side heat flux
exceeding 2.0 Btu/ft.sup.2 for four minutes.
[0013] The flame propagation test referred to herein uses heat from
a radiant panel and a pilot flame and is performed similarly to the
current ASTM E 648 test procedures and performance criteria. Like
the FAA medium scale burn through test, the flame propagation test
(hereinafter referred to as "the flame propagation test") is
defined on the www.fire.tc.faa.gov web site. In the flame
propagation test a pilot flame is applied at a zero point, for a
period of fifteen seconds, to a horizontally oriented sample sheet.
To pass the test, the flame must not propagate more than two inches
beyond the point of contact (the zero point) between the pilot
flame and the sample sheet and the sample sheet must not support
continued combustion after the pilot flame is removed (there can be
on evident flaming after the pilot flame is removed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIGS. 1-9 are schematic cross sections through different
embodiments of the burn through, flame propagation and, preferably,
water vapor transmission resistant layer or covering of the present
invention.
[0015] FIG. 10 is a schematic perspective view of the burn through,
flame propagation and, preferably, water vapor transmission
resistant layer or covering of the present invention used as a bag
or envelope to enclose, encapsulate or contain a thermal and
acoustical insulation material.
[0016] FIG. 11 is a cross section of FIG. 10, taken substantially
along lines 11-11 of FIG. 10.
[0017] FIG. 12 is a partial schematic cross section through an
insulation system where the burn through, flame propagation and,
preferably, water vapor transmission resistant layer or covering of
the present invention overlays a layer of insulation material.
[0018] FIG. 13 is a partial schematic cross section through an
insulation system where burn through, flame propagation and,
preferably, water vapor transmission resistant layers or coverings
of the present invention overlay, are interleaved between and are
overlaid by layers of insulation material.
[0019] FIG. 14 is a partial schematic horizontal cross section
through an aircraft fuselage with the burn through, flame
propagation, and, preferably, water vapor transmission resistant
layer or covering forming the outboard layer of a thermal and
acoustical insulation system.
[0020] FIG. 15 is a partial schematic horizontal cross section
through an aircraft fuselage with the burn through, flame
propagation, and, preferably, water vapor transmission resistant
layer or covering forming the inboard layer of a thermal and
acoustical insulation system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] The laminates 120, 220, 320, 420, 520, 620 and 720 of the
burn through, flame propagation and, preferably, water vapor
transmission resistant layer or covering of the present invention,
schematically illustrated in FIGS. 1-7, include a sheet of burn
through and flame propagation resistant paper 22 (burn through
barrier paper 22) and a sheet of polymeric film 24, which is
preferably, flame propagation and water vapor transmission
resistant, bonded to one or both major surfaces of the burn through
barrier paper 22. FIG. 7 shows a laminate 720 which includes a
separate scrim layer. The laminates 120-620 may also include a
separate scrim layer or a polymeric film 24 reinforced with scrim
for added strength, especially added puncture and tear
resistance.
[0022] The sheet of burn through barrier paper 22 includes aromatic
polyamide (aramid) fibers, mica flakes and aromatic polyamide
(aramid) fibrid binder. Preferably, the barrier paper 22 contains
between 30% and 50% by weight mica flakes and, typically, between
25% and 35% by weight aramid fibers and between 25% and 35% aramid
fibrid binder. The barrier paper is made by a wet laid paper making
process which combines the aramid fibers, the mica flakes and the
aramid fibrid binder. The barrier paper, thus produced, can be
calendared to align the mica flakes, reduce the paper thickness and
provide improved burn through protection. While lighter weight
barrier papers may be possible, the barrier paper typically weighs
about 89 grams per square meter (89 g/m.sup.2). An example of such
a burn through barrier paper is a paper made and sold by E. I.
DuPont de Nemours & Co. of Wilmington, Del. under the trade
designation NOMEX.RTM. M Type 418 paper.
[0023] To provide additional water repellency to the barrier paper
22, the barrier paper 22 may be treated by dipping, spray or roll
coating the barrier paper 22 with a fluorocarbon or similar water
repellant, such as but not limited to a perfluorooctanyl. An
example of such a water repellant is sold by The 3M Company of St.
Paul, Minn. under the trade designation "SCOTCHGUARD.RTM.".
[0024] The barrier paper 22 is adhesively bonded or heat sealed to
one or two sheets of polymeric film 24 which preferably are water
vapor transmission and flame propagation resistant. Polyester films
are an example of films that are water vapor transmission resistant
but not flame propagation resistant. Polyvinylfluoride films and
polyimide films are examples of polymeric films 24 which are both
water vapor transmission and flame propagation resistant. These
flame propagation resistant films resist flame propagation and,
preferably, when one of these films, extending horizontally, is
exposed to a pilot flame, the flame propagates no more than 2
inches beyond the point of flame contact in fifteen seconds. When
an open flame is removed from contact with such films, these films
do not support continued combustion and cease to burn (no continued
flaming is evident). Commercially available examples of these films
are films sold by E. I. DuPont de Nemours & Co. of Wilmington,
Del., such as, a polyester film sold under the trade designation
MYLAR.RTM.; a polyvinylfluoride film sold under the trade
designation TEDLAR.RTM.; and a polyimide film sold under the trade
designation KAPTON.RTM.. The film or films 24 are typically from
0.2 to 1.0 mils thick and typically weigh between 20 and 50
g/m.sup.2. The light weight of the films 24 is due in part to the
elimination of a reinforcing scrim from the film. With the film or
films 24 adhesively bonded or heat sealed to the burn through
barrier paper 22, the burn through barrier paper 22 reinforces the
film or films 24 and a scrim may no longer needed in the film or
films for certain applications. Preferably, the film 24 has a
permeability in perms of 4.0 or less and more preferably, a
permeability of 2.5 perms or less. The polyvinylfluoride and the
polyimide film can be metallized, e.g. by condensing an aluminum
vapor on the film, to reduce the permeability of the film.
[0025] Preferably, the burn through barrier paper 22 and the
polymeric film or films 24 are bonded together by a layer or layers
of heat and/or ultrasonically sealable adhesive, e.g. a polyester
based adhesive, with fire retardant additives, located intermediate
the major surfaces of the barrier paper 22 and film(s) 24. Examples
of such heat and/or ultrasonically sealable adhesives are adhesives
sold by Bostik Incorporated, of Middleton, Massachusetts, under the
trade designations BOSTIK THERMOGRIP.RTM. 1101, 1165 and 1175.
[0026] The burn through, flame propagation, and, preferably, water
vapor transmission resistant laminated sheet 120, shown in FIG. 1,
includes a sheet of burn through barrier paper 22 and a sheet of
polymeric film 24 with a major surface of the film bonded, e.g. by
a heat sealable adhesive, to a major surface of the burn through
barrier paper 22. While the bonding of the polymeric film 24 to the
burn through barrier paper 22 may enhance the abrasion resistance
and the durability of the burn through barrier paper 22,
preferably, the polymeric film 24 is a flame propagation and water
vapor transmission resistant film. When the polymeric film 24 is
flame propagation resistant, the film 24 can be on the side of the
laminated sheet 120 expected to face the flame front of a fire.
When the polymeric film 24 is water vapor transmission resistant,
the film 24 restricts the transmission of water vapor through the
laminated sheet 120. When the polymeric film 24 is flame
propagation and water vapor transmission resistant and the
laminated sheet 120 is formed into a bag or envelope containing
insulation, such as but not limited to the bag or envelope of FIGS.
10 and 11, the polymeric film 24 resists the transmission of water
vapor into the burn through barrier paper 22 of the laminated sheet
120 and through the laminated sheet 120 into any insulation
contained or encapsulated within bags or envelopes formed from the
laminated sheet 120. By restricting the accumulation of water in
the burn through barrier paper 22, the integrity of the burn
through barrier paper 22 and the laminated sheet 120 is better
preserved and by restricting the accumulation of water in the
insulation encapsulated within bags or envelopes formed from the
laminated sheet 120 the thermal and acoustical properties of an
insulation system including the encapsulated insulation are better
preserved and a build up of weight within the insulation system
which would adversely affect the performance of an aircraft is
avoided.
[0027] Where the polymeric film 24 of the laminated sheet 120 is a
polyvinylfluoride or a polyimide film, the laminated sheet 120 can
be oriented with the film 24 of the laminated sheet on the cold or
inboard side of the laminated sheet (the side of the laminated
sheet expected to face away from any fire) and the burn through
barrier paper 22 on the hot or outboard side of the laminated sheet
(the side of the laminated sheet expected to face toward any fire)
or with the burn through barrier paper 22 on the cold side of the
laminated sheet and the polymeric film 24 on the hot side of the
laminated sheet. Preferably, where the polymeric film 24 of the
laminate sheet 120 is a polyester film, the laminated sheet 120 is
oriented with the polymeric film 24 on the cold side of the
laminated sheet and the burn through barrier paper 22 on the hot
side of the laminated sheet so that the burn through barrier paper
22 provides the flame propagation resistance. Likewise, where a
polymeric film 24 of any of the other laminated sheets 220 to 620,
is a polyvinylfluoride or a polyimide film, that laminated sheet
may be oriented with the polymeric film 24 on the side of the
laminated sheet expected to face any fire and where the polymeric
film 24 of any of the other laminated sheets 220-620 is a polyester
film, that laminated sheet should, preferably, be oriented with the
polymeric film 24 on the side of the laminated sheet expected to
face away from any fire.
[0028] The burn through, flame propagation, and, preferably, water
vapor transmission resistant laminated sheet 220, shown in FIG. 2,
includes a sheet of burn through barrier paper 22 and two sheets of
polymeric film 24 with major surfaces of the polymeric films 24
bonded, e.g. by a heat sealable adhesive, to the two major surfaces
of the burn through barrier paper 22. While the bonding of the
polymeric films 24 to the burn through barrier paper 22 may enhance
the abrasion resistance and the durability of the burn through
barrier paper 22, preferably, at least one of the polymeric films
24 is a flame propagation and water vapor transmission resistant
film. When one of the polymeric films 24 is flame propagation
resistant, that polymeric film 24 can be on the side of the
laminated sheet 220 expected to face the flame front of a fire.
When one of the polymeric films 24 is water vapor transmission
resistant, the polymeric film 24 restricts the transmission of
water vapor through the laminated sheet 220. When one of the
polymeric films 24 is flame propagation and water vapor
transmission resistant and the laminated sheet 220 is formed into a
bag or envelope containing insulation, such as but not limited to
the bag or envelope of FIGS. 10 and 11, with the outside surface of
the bag or envelope formed from the flame propagation and water
vapor transmission resistant polymeric film 24, that polymeric film
24 resists the transmission of water vapor into the burn through
barrier paper 22 of the laminated sheet 220 and through the
laminated sheet 220 into any insulation contained or encapsulated
within bags or envelopes formed from the laminated sheet 220. By
restricting the accumulation of water in the burn through barrier
paper 22, the integrity of the burn through barrier paper 22 and
the laminated sheet 220 is better preserved and by restricting the
accumulation of water in the insulation encapsulated within bags or
envelopes formed from the laminated sheet 220 the thermal and
acoustical properties of an insulation system including the
encapsulated insulation are better preserved and a build up of
weight within the insulation system which would adversely affect
the performance of an aircraft is avoided.
[0029] The burn through, flame propagation, and, preferably, water
vapor transmission resistant laminated sheet 320, shown in FIG. 3,
includes a sheet of burn through barrier paper 22, a sheet
polymeric film 24 with a major surface of the film bonded, e.g. by
a heat sealable adhesive, to a major surface of the burn through
barrier paper 22, and a heat sealable adhesive coating 26 on and
coextensive with the polymeric film 24. The heat sealable adhesive
coating 26 enables the burn through, flame propagation and,
preferably, water vapor transmission resistant laminated sheet 320
to be bonded: to itself or another laminated sheet 320 when formed
into a bag or envelope to contain or encapsulate insulation; to
insulation material to which the laminate 320 is applied; or to a
structural component, e.g. the framework, skin or trim panels of an
aircraft fuselage. Examples of heat sealable adhesive coatings that
may be used are polyester based adhesives with fire retardant
additives and polyvinylfluoride based adhesives. The heat sealable
adhesive coating 26 typically weighs between 20 and 100
g/m.sup.2.
[0030] While the bonding of the polymeric film 24 to the burn
through barrier paper 22 in the laminated sheet 320 may enhance the
abrasion resistance and the durability of the burn through barrier
paper 22, preferably, the polymeric film 24 is a flame propagation
and water vapor transmission resistant film. When the polymeric
film 24 is flame propagation resistant, the polymeric film 24 can
be on the side of the laminated sheet 320 expected to face the
flame front of a fire. When the polymeric film 24 is water vapor
transmission resistant, the polymeric film 24 restricts the
transmission of water vapor through the laminated sheet 320. When
the polymeric film 24 is flame propagation and water vapor
transmission resistant and the laminated sheet 320 is formed into a
bag or envelope containing insulation, such as but not limited to
the bag or envelope of FIGS. 11 and 12, the polymeric film 24
resists the transmission of water vapor into the burn through
barrier paper 22 of the laminated sheet 320 and through the
laminated sheet 320 into any insulation contained or encapsulated
within bags or envelopes formed from the laminated sheet 320. By
restricting the accumulation of water in the burn through barrier
paper 22, the integrity of the burn through barrier paper 22 and
the laminated sheet 320 is better preserved and by restricting the
accumulation of water in the insulation encapsulated within bags or
envelopes formed from the laminated sheets 320 the thermal and
acoustical properties of an insulation system including the
encapsulated insulation are better preserved and a build up of
weight within the insulation system which would adversely affect
the performance of an aircraft is avoided.
[0031] The burn through, flame propagation, and, preferably, water
vapor transmission resistant laminated sheet 420, shown in FIG. 4,
includes a sheet of burn through barrier paper 22, a sheet of
polymeric film 24 with a major surface of the film bonded, e.g. by
a heat sealable adhesive, to a first major surface of the burn
through barrier paper 22, and a heat sealable adhesive coating 26
applied to and coextensive with a second major surface of the burn
through barrier paper 22. The heat sealable adhesive coating 26
enables the burn through, flame propagation and water vapor
transmission resistant laminated sheet 420: to be bonded to itself
or another laminated sheet 420 when formed into a bag or envelope
for containing or encapsulating insulation; to insulation material
to which the laminated sheet 420 is applied; or to a structural
component, e.g. the framework, skin or trim panels of an aircraft
fuselage. Examples of heat sealable adhesive coatings that may be
used are polyester based adhesives with fire retardant additives
and polyvinylfluoride based adhesives. The heat sealable adhesive
coating 26 typically weighs between 20 and 100 g/m.sup.2 (dry
weight).
[0032] While the bonding of the polymeric film 24 to the burn
through barrier paper 22 in the laminated sheet 420 may enhance the
abrasion resistance and the durability of the burn through barrier
paper 22, preferably, the polymeric film 24 is a flame propagation
and water vapor transmission resistant film. When the polymeric
film 24 is flame propagation resistant, the polymeric film 24 can
be on the side of the laminated sheet 420 expected to face the
flame front of a fire. When the polymeric film 24 is water vapor
transmission resistant, the polymeric film restricts water vapor
transmission through the laminated sheet 420. When the polymeric
film 24 is flame propagation and water vapor transmission resistant
and the laminated sheet 420 is formed into a bag or envelope
containing insulation, such as but not limited to the bag or
envelope of FIGS. 10 and 11, the polymeric film 24 resists the
transmission of water vapor into the burn through barrier paper 22
of the laminated sheet 420 and through the laminated sheet 420 into
any insulation contained or encapsulated within bags formed from
the laminated sheet 420. By restricting the accumulation of water
in the burn through barrier paper 22, the integrity of the burn
through barrier paper 22 and the laminated sheet 420 is better
preserved and by restricting the accumulation of water in the
insulation encapsulated within bags or envelopes formed from the
laminated sheet 420 the thermal and acoustical properties of an
insulation system including the encapsulated insulation are better
preserved and a build up of weight within the insulation system
which would adversely affect the performance of an aircraft is
avoided.
[0033] The burn through, flame propagation, and, preferably, water
vapor transmission resistant laminated sheet 520, shown in FIG. 5,
includes a sheet of burn through barrier paper 22, a sheet of
polymeric film 24 with a major surface of the film bonded, e.g by a
heat sealable adhesive, to a first major surface of the burn
through barrier paper 22, a heat sealable adhesive coating 26
applied to and coextensive with a second major surface of the burn
through barrier paper 22, and a heat sealable adhesive coating 26
applied to and coextensive with a second major surface of the sheet
of polymeric film 24. The heat sealable adhesive coatings 26 enable
the burn through, flame propagation and water vapor transmission
resistant laminated sheet 520 to be bonded: to itself or another
laminated sheet when formed into a bag or envelope for containing
or encapsulating insulation; to insulation material to which the
laminate 520 is applied; or to a structural component, e.g. the
framework, skin or trim panels of an aircraft fuselage. Examples of
heat sealable adhesive coatings that may be used are polyester
based adhesives with fire retardant additives and polyvinylfluoride
based adhesives. The heat sealable adhesive coatings 26 typically
weigh between 20 and 100 g/m.sup.2 (dry weight).
[0034] While the bonding of the polymeric film 24 to the burn
through barrier paper 22 in the laminated sheet 520 may enhance the
abrasion resistance and the durability of the burn through barrier
paper 22, preferably, the polymeric film 24 is a flame propagation
and water vapor transmission resistant film. When the polymeric
film 24 is flame propagation resistant, the polymeric film 24 can
be on the side of the laminated sheet 520 expected to face the
flame front of a fire. When the polymeric film 24 is water vapor
transmission resistant, the film 24 restricts the transmission of
water vapor through the laminated sheet 520. When the polymeric
film 24 is flame propagation and water vapor transmission resistant
and the laminated sheet 520 is formed into a bag or envelope
containing insulation, such as but not limited to the bag or
envelope of FIGS. 10 and 11, the polymeric film 24 resists the
transmission of water vapor into the burn through barrier paper 22
of the laminated sheet 520 and through the laminated sheet 520 into
any insulation contained or encapsulated within bags or envelopes
formed from the laminated sheet 520. By restricting the
accumulation of water in the burn through barrier paper 22, the
integrity of the burn through barrier paper 22 and the laminated
sheet 520 is better preserved and by restricting the accumulation
of water in the insulation encapsulated within bags or envelopes
formed from the laminated sheet 520 the thermal and acoustical
properties of an insulation system including the encapsulated
insulation are better preserved and a build up of weight within the
insulation system which would adversely affect the performance of
an aircraft is avoided.
[0035] The burn through, flame propagation, and, preferably, water
vapor transmission resistant laminated sheet 620, shown in FIG. 6,
includes a sheet of burn through barrier paper 22, two sheets of
polymeric film 24 with major surfaces of the films bonded, e.g. by
a heat sealable adhesive, to the two major surfaces of the burn
through barrier paper 22, and heat sealable adhesive coatings 26
overlaying and coextensive each sheet of the polymeric film 24. The
heat sealable adhesive coatings 26 enable the burn through, flame
propagation and water vapor transmission resistant laminated sheet
620: to be bonded to itself or another laminated sheet 620 when
formed into a bag or envelope for containing or encapsulating
insulation; to insulation material to which the laminated sheet 620
is applied; or to a structural component, e.g. the framework, skin
or trim panels of an aircraft fuselage. Examples of heat sealable
adhesive coatings that may be used are polyester based adhesives
with fire retardant additives and polyvinylfluoride based
adhesives. While the heat sealable adhesive coatings are shown
applied to both sheets 24 of the polymeric film, the heat sealable
adhesive may be applied to only one of the sheets of polymeric film
24. The heat sealable coatings 26 typically weigh between 20 and
100 g/m.sup.2 (dry weight).
[0036] While the bonding of the polymeric films 24 to the burn
through barrier paper 22 in the laminated 620 may enhance the
abrasion resistance and the durability of the burn through barrier
paper 22, preferably, at least one of the polymeric films 24 is a
flame propagation and water vapor transmission resistant film. When
one of the polymeric films 24 is flame propagation resistant, that
polymeric film 24 can be on the side of the laminated sheet 620
expected to face the flame front of a fire. When one of the
polymeric films 24 is water vapor transmission resistant, that
polymeric film 24 restricts the transmission of water vapor through
the laminated sheet 620. When one of the polymeric films 24 is
flame propagation and water vapor transmission resistant and the
laminated sheet 620 is formed into a bag or envelope containing
insulation, such as but not limited to the bag or envelope of FIGS.
10 and 11, with the outside surface of the bag formed from the
flame propagation and water vapor transmission resistant polymeric
film 24, that polymeric film 24 resists the transmission of water
vapor into the burn through barrier paper 22 of the laminated sheet
620 and through the laminated sheet 620 into any insulation
contained or encapsulated within bags or envelopes formed from the
laminated sheet 620. By restricting the accumulation of water in
the burn through barrier paper 22, the integrity of the burn
through barrier paper 22 and the laminated sheet 620 is better
preserved and by restricting the accumulation of water in the
insulation encapsulated within bags or envelopes formed from the
laminated sheet 620 the thermal and acoustical properties of an
insulation system including the encapsulated insulation are better
preserved and a build up of weight within the insulation system
which would adversely affect the performance of an aircraft is
avoided.
[0037] The burn through, flame propagation, and preferably, water
vapor transmission resistant laminated sheet 720, shown in FIG. 7,
includes a sheet of burn through barrier paper 22, a sheet of
polymeric film 24 with a first major surface of the film bonded to
a major surface of the burn through barrier paper 22, and a sheet
of scrim 28 bonded to a second major surface of the polymeric film
24 e.g. by a heat sealable adhesive. Other than the scrim 28 bonded
to the sheet of polymeric film 24 to increase the puncture and tear
resistance to the laminated sheet, the laminated sheet 720 is the
same as laminated sheet 120. While not shown, the laminated sheets
220, 320, 420, 520 and 620 may also have a sheet or layer of scrim
28 overlaying and adhesively bonded to the burn through barrier
paper 22, intermediate and bonded to both the burn through barrier
paper 22 and the sheet or one of the sheets of polymeric film 24,
or overlaying and bonded to the sheet or one of the sheets of
polymeric film 24. Other than the inclusion of the scrim 28 to
increase the puncture and tear resistance of the laminated sheets,
the laminated sheets 220-620 would otherwise be the same.
Commercially available Nylon, NOMEX, polyester, glass scrims and
other similar scrims may be used as the scrims for laminated sheets
120 to 720. Instead of incorporating the reinforcing scrims in the
laminated sheets 120-620 as separate layers, the reinforcing scrims
may also be incorporated into the laminated sheets 120-620 by using
scrim reinforced polymeric films 24.
[0038] The burn through, flame propagation and water vapor
transmission resistant sheets, layers or coverings 820 and 920 of
the present invention, schematically illustrated in FIGS. 8 and 9,
include a sheet of the burn through barrier paper 22 which is
treated with a heat and/or ultrasonically sealable, water vapor and
flame propagation resistant polyvinylfluoride water based emulsion
(heat sealable adhesive). Preferably, the burn through, flame
propagation and water vapor transmission resistant sheets 820 and
920 have a permeability of 4.0 perms or less and, more preferably,
a permeability of 2.5 perms or less. In addition, a sheet or layer
of scrim 28 is bonded to one major surface of the burn through
barrier paper 22 in the sheet 920 of FIG. 9, preferably, with the
heat sealable emulsion, to increase the puncture and tear
resistance of the sheet 920. While not shown, the sheet 820 of FIG.
8 could also include a layer or sheet of scrim bonded to one major
surface of the burn through barrier paper 22. Commercially
available Nylon, NOMEX, polyester and glass scrims may be used as
the scrims for sheets 820 to 920. The sheet of burn through barrier
paper 22 may be dip, spray or roll coated on one or both major
surfaces, as shown in FIGS. 8 and 9, respectively, with the heat
sealable, water vapor and flame propagation resistant
polyvinylfluoride water based emulsion. Preferably, the heat
sealable, water vapor transmission and flame propagation resistant
polyvinylfluoride water based emulsion coating(s) 30 weigh between
20 and 100 g/m.sup.2 (dry weight). Coating the burn through barrier
paper 22 with the heat sealable, water vapor and flame propagation
resistant polyvinylfluoride water based emulsion has several
benefits. The polyvinylfluoride water based emulsion can enhance
the durability and flexibility of the burn through barrier paper
22. The polyvinylfluoride water based emulsion can provide the
water vapor transmission resistance required of the sheets when
used to form the insulation bags or envelopes for most aircraft
without the use of the sheet(s) of polymeric film 24. Since the
polyvinylfluoride water based emulsion is heat sealable, the
polyvinylfluoride water based emulsion coating(s) can be used: to
bond the burn through, flame propagation and water vapor
transmission resistant sheets 820 and 920 to themselves or another
sheet 820 or 920 to form a bag or envelope to contain or
encapsulate insulation material; to insulation material to which
the sheets 820 and 920 are applied; or to a structural component,
e.g. the framework, skin or trim panels of an aircraft fuselage.
The polyvinylfluoride water based emulsion also has excellent fire
resistance and low toxic gas evolution during combustion. An
example of a heat sealable, water vapor and flame propagation
resistant polyvinylfluoride water based emulsion is a
polyvinylfluoride water based emulsion sold by Elf Atochem North
America, Inc. of King of Prussia, Pa. under the trade designation
KYNAR.RTM..
[0039] When the burn through, flame propagation and water vapor
transmission resistant sheet 820 is formed into a bag or envelope
containing insulation, such as but not limited to the bag or
envelope of FIGS. 10 and 11, with the coated surface forming the
outer surface of the bag or envelope or when the burn through,
flame propagation and water vapor transmission resistant sheet 920
is formed into a bag or envelope, such as but not limited to the
bag or envelope of FIGS. 10 and 11, the heat and/or ultrasonically
sealable, water vapor and flame propagation resistant
polyvinylfluoride water based emulsion coating 30 restricts the
transmission of water vapor into the burn through barrier paper 22
of the sheet 820 or 920 and through the sheet 820 or 920 into any
insulation contained or encapsulated within bags or envelopes
formed from the sheets 820 or 920. By restricting the accumulation
of water in the burn through barrier paper 22, the integrity of the
burn through barrier paper 22 and the sheet 820 or 920 is better
preserved and by restricting the accumulation of water in the
insulation encapsulated within bags or envelopes formed from the
sheet 820 or 920 the thermal and acoustical properties of an
insulation system including the encapsulated insulation are better
preserved and a build up of weight within the insulation system
which would adversely affect the performance of an aircraft is
avoided.
[0040] In addition to other applications where burn through and
flame propagation resistance or where burn through, flame
propagation and water vapor transmission resistance is desired or
required, the burn through, flame propagation and water vapor
transmission resistant layers or coverings 120 to 920 may be used
to form a bag or envelope 40 that encloses, contains or
encapsulates a layer of thermal and acoustical insulation material
42, such as one or more light weight, flexible glass fiber
insulation blankets or one or more sheets of polyimide foam, as
shown in FIGS. 10 and 11. The bag or envelope 40 shown in FIGS. 10
and 11 includes two sheets 44 and 46 of one of the layers or
coverings 120 to 920 which are heat sealed or otherwise bonded
together at the tab 48 to form the bag or envelope 40. While, as
shown, two sheets 44 and 46 of the layers or coverings 120 to 920
are used to form the bag or envelope 40 containing the insulation
42, the bag or envelope 40 could be made from one sheet of layers
or coverings 120 to 920. As shown in FIGS. 12 and 13, for certain
applications, one or more sheets 50 of layers or coverings 120 to
920 may also overlay, be overlaid by or be located intermediate
major surfaces of layer(s) of thermal and acoustical insulation 42,
such as light weight, flexible, glass fiber or polyimide foam
insulation material. While not shown, the sheets 50 may also
overlay the side and end edges of the insulation layer(s) as well
as the major surface(s) of the insulation layer(s).
[0041] Examples of light weight, flexible, glass fiber and foam
insulation materials which may be included in thermal and
acoustical insulation systems utilizing the burn through, flame
propagation and, preferably, water vapor transmission resistant
layers or coverings 120 to 920 as covering to totally or partially
encapsulate or contain the insulation materials or as layers
overlaying, overlaid by or intermediate layer(s) of thermal and
acoustical insulation are light weight, flexible glass fiber
insulation materials sold by Johns Manville International, Inc.
under the trade designations MICROLITE AA.RTM. (a 1.5pcf, 0.6pcf or
0.42pcf insulation) and MICROLITE AA.RTM. Premium NR fiber glass (a
1.2pcf, 0.5pcf or 0.34pcf insulation) and polyimide foam sold by
In-Spec-Foam of Plano, Tex., under the trade designation
INSULMIDE.RTM.).
[0042] FIGS. 14 and 15 schematically show insulation systems for an
aircraft fuselage 60 wherein the insulation is located in a cavity
of the fuselage intermediate the outer skin 66 and framework 68 of
the fuselage 60 and the trim panels 70 of the aircraft cabin. As
shown in FIG. 14, a sheet 62 of the one of the layers or coverings
120 to 920 is located intermediate bags 64 of insulation in the
cavities of the aircraft fuselage and the outer skin 66 and
framework 68 of the fuselage (on the outboard side of the bags of
insulation) to provide a burn through, flame propagation, and
preferably, water vapor transmission resistant barrier. As shown in
FIG. 15, a sheet 62 of the one of the layers or coverings 120 to
920 is located intermediate bags 64 of insulation in the cavities
of the aircraft fuselage and the trim panels 70 of the aircraft
cabin (on the inboard side of the bags of insulation) to provide a
burn through, flame propagation, and preferably, water vapor
transmission resistant barrier. The sheets 62 of FIGS. 14 and 15
are secured to the aircraft fuselage by pins, clamps or other
conventional fastening means used in the aircraft industry.
[0043] Thermal and acoustical insulation systems were tested
utilizing burn through, flame propagation and water vapor
transmission resistant laminate coverings of the present invention.
The laminates (System Samples 1-8) each included a sheet of mica
filled NOMEX.RTM.M type 418 paper with a sheet of film bonded to
the paper by a heat sealable adhesive coating. The laminates were
used as coverings for both the inboard or cold side and the
outboard or hot side of the systems. Two layers of lightweight
(0.42 pounds/ft.sup.3), flexible glass fiber insulation (glass
fiber insulation sold by Johns Manville International, Inc. of
Denver, Colo., under the trade designation MICROLITE AA.RTM.
insulation) were contained between the laminate coverings.
[0044] The System samples were subjected to the FAA medium scale
burn through test and the flame propagation test. The FAA medium
scale burn through test is passed when there are 240 or more
seconds to failure and the heat flux at both locations on the cold
side specified in the test (Flux 1 and 2) at 240 seconds is less
than 2.0 Btu/ft.sup.2/second. Seven of the eight system samples
passed the FAA medium scale burn through test and all of the system
samples passed the flame propagation test.
1 SYSTEM SAMPLES TESTED MATERIAL LAMINATE SYSTEM DESCRIPTION WEIGHT
g/m.sup.2 WEIGHT g/m.sup.2 System Sample 1 0.5 mil metallized pvf/
180 702 5 mil NOMEX .RTM. M paper/ Heat Seal Coating System Sample
2 0.5 mil metallized pvf/ 208 758 5 mil NOMEX .RTM. M paper/
Polyester/Scrim/Heat Seal Coating System Sample 3 0.75 mil
Polyimide film/ 163 668 5 mil NOMEX .RTM. M paper/
Polyester/Scrim/Heat Seal Coating System Sample 4 0.5 mil
metallized pvf/ 157 656 3 mil NOMEX .RTM. M paper/
Polyester/Scrim/Heat Seal Coating System Sample 5 0.5 mil
metallized pvf/ 124 590 3 mil NOMEX .RTM. M paper/ Heat Seal
Coating System Sample 6 0.75 mil Polyimide film/ 161 664 3 mil
NOMEX .RTM. M paper/ Polyester/Scrim/Heat Seal Coating System
Sample 7 0.75 mil Polyimide film/ 134 610 3 mil NOMEX .RTM. M
paper/ Heat Seal Coating System Sample 8 0.75 mil Polyimide film/
194 730 5 mil NOMEX .RTM. M paper/ Heat Seal Coating pvf =
polyvinylfluoride film Heat Seal Coating = heat sealable polyester
based adhesive
[0045]
2 BURN THROUGH TEST BURN THROUGH MATERIAL DESCRIPTION SECONDS FLUX
1 FLUX 2 System Sample 1 0.5 mil metallized pvf/ >360 0.75 1.22
5 mil NOMEX .RTM. M paper/ @240 0.4 0.7 Heat Seal Coating System
Sample 2 0.5 mil metallized pvf/ >360 0.69 0.59 5 mil NOMEX
.RTM. M paper/ @240 0.5 0.4 Polyester/Scrim/Heat Seal Coating
System Sample 3 0.75 mil Polyimide film/ 330 1.56 1.4 5 mil NOMEX
.RTM. M paper/ @240 0.9 1.3 Polyester/Scrim/Heat Seal Coating
System Sample 4 0.5 mil metallized pvf/ 150 1.9 0.7 3 mil NOMEX
.RTM. M paper/ Polyester/Scrim/Heat Seal Coating System Sample 5
0.5 mil metallized pvf/ 285 1.4 1.25 3 mil NOMEX .RTM. M paper/
@240 1.1 0.8 Heat Seal Coating System Sample 6 0.75 mil Polyimide
film/ >360 1.7 1.1 3 mil NOMEX .RTM. M paper/ @240 1.4 0.6
Polyester/Scrim/Heat Seal Coating System Sample 7 0.75 mil
Polyimide film/ 255 2.3 1.3 3 mil NOMEX .RTM. M paper/ @240 1.7 1.2
Heat Seal Coating System Sample 8 0.75 mil Polyimide film/ >360
1.02 0.61 5 mil NOMEX .RTM. M paper/ @240 0.4 0.4 Heat Seal Coating
Flux = Btu/ft.sup.2/second
[0046] In describing the invention, certain embodiments have been
used to illustrate the invention and the practices thereof.
However, the invention is not limited to these specific embodiments
as other embodiments and modifications within the spirit of the
invention will readily occur to those skilled in the art on reading
this specification. Thus, the invention is not intended to be
limited to the specific embodiments disclosed, but is to be limited
only by the claims appended hereto. water based emulsion.
* * * * *
References