U.S. patent application number 16/563642 was filed with the patent office on 2019-12-26 for fire barrier layer and fire barrier film laminate.
The applicant listed for this patent is UNIFRAX I, LLC. Invention is credited to Joseph A. FERNANDO, Chad E. GARVEY, Kenneth B. MILLER, Robert RIOUX.
Application Number | 20190389186 16/563642 |
Document ID | / |
Family ID | 46064622 |
Filed Date | 2019-12-26 |
United States Patent
Application |
20190389186 |
Kind Code |
A1 |
FERNANDO; Joseph A. ; et
al. |
December 26, 2019 |
FIRE BARRIER LAYER AND FIRE BARRIER FILM LAMINATE
Abstract
A fire barrier laminate including: at least one non-fibrous fire
barrier layer directly or indirectly coated onto at least one first
polymeric flame propagation resistant film layer; at least one
second film layer proximate to the non-fibrous fire barrier layer
opposite the first polymeric flame propagation resistant film
layer; at least one scrim layer disposed: (i) between the
non-fibrous fire barrier layer and the first polymeric flame
propagation resistant film layer; and/or (ii) between the
non-fibrous fire barrier layer and the second film layer; and/or
(iii) proximate to the first polymeric flame propagation resistant
film layer opposite the non-fibrous fire barrier layer; and/or (iv)
proximate to the second film layer opposite the non-fibrous fire
barrier layer. Also, a method of making the fire barrier
laminate.
Inventors: |
FERNANDO; Joseph A.;
(Amherst, NY) ; GARVEY; Chad E.; (Lewiston,
NY) ; RIOUX; Robert; (Amherst, NY) ; MILLER;
Kenneth B.; (Lockport, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
UNIFRAX I, LLC |
Tonawanda |
NY |
US |
|
|
Family ID: |
46064622 |
Appl. No.: |
16/563642 |
Filed: |
September 6, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15198910 |
Jun 30, 2016 |
10434755 |
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16563642 |
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13707999 |
Dec 7, 2012 |
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15198910 |
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13299399 |
Nov 18, 2011 |
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13707999 |
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61415552 |
Nov 19, 2010 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 5/028 20130101;
B32B 2307/718 20130101; B32B 7/12 20130101; B32B 27/12 20130101;
B32B 2255/10 20130101; B32B 2262/101 20130101; B32B 27/08 20130101;
B32B 2605/18 20130101; B32B 37/02 20130101; B32B 2605/00 20130101;
B32B 37/12 20130101; Y10T 156/10 20150115; Y10T 442/10 20150401;
B32B 2307/3065 20130101; B32B 2307/7265 20130101; B32B 2307/304
20130101; B32B 2038/0092 20130101; B32B 2307/102 20130101; B32B
3/04 20130101 |
International
Class: |
B32B 27/12 20060101
B32B027/12; B32B 7/12 20060101 B32B007/12; B32B 5/02 20060101
B32B005/02; B32B 27/08 20060101 B32B027/08; B32B 37/02 20060101
B32B037/02 |
Claims
1. A fire barrier laminate comprising: at least one non-fibrous
fire barrier layer comprising an inorganic platelet material,
wherein the inorganic platelet material comprises at least one of
vermiculite, mica, clay or talc; at least one first polymeric flame
propagation resistant film layer proximate to the non-fibrous fire
barrier layer; at least one second film layer proximate to the
non-fibrous fire barrier layer opposite the first polymeric flame
propagation resistant film layer; and at least one scrim layer
disposed: (i) between the non-fibrous fire barrier layer and the
first polymeric flame propagation resistant film layer; and/or (ii)
between the non-fibrous fire barrier layer and the second film
layer; and/or (iii) proximate to the first polymeric flame
propagation resistant film layer opposite the non-fibrous fire
barrier layer; and/or (iv) proximate to the second film layer
opposite the non-fibrous fire barrier layer; wherein the
non-fibrous fire barrier layer comprises from about 20% to less
than 100% by weight of the inorganic platelet material, from
greater than 0% to about 40% by weight of the organic binder and/or
inorganic binder, and from 0% to about 50% of the functional
filler.
2. The fire barrier laminate of claim 1, wherein the fire barrier
laminate further comprises at least one adhesive layer adhering the
non-fibrous fire barrier layer to the first polymeric flame
propagation resistant film layer.
3. The fire barrier laminate of claim 1, wherein the fire barrier
laminate further comprises at least one adhesive layer adhering the
scrim layer to at least one of the non-fibrous fire barrier layer,
the first polymeric flame propagation resistant film layer, or the
second film layer.
4. The fire barrier laminate of claim 1, wherein the non-fibrous
fire barrier layer comprises vermiculite in an amount from about 20
to about 100 weight percent, based on the total weight of the
non-fibrous fire barrier layer.
5. The fire barrier laminate of claim 1, wherein the non-fibrous
fire barrier layer comprises vermiculite in an amount of about 100
weight percent, based on the total weight of the non-fibrous fire
barrier layer.
6. The fire barrier laminate of claim 1, wherein the non-fibrous
fire barrier layer comprises mica in an amount from about 20 to
about 100 weight percent, based on the total weight of the
non-fibrous fire barrier layer.
7. The fire barrier laminate of claim 1, wherein the non-fibrous
fire barrier layer comprises mica in an amount of about 100 weight
percent, based on the total weight of the non-fibrous fire barrier
layer.
8. The fire barrier laminate of claim 1, wherein the fire barrier
laminate has a basis weight of about 80 gsm to about 120 gsm.
9. The fire barrier laminate of claim 1, wherein the fire barrier
laminate has a basis weight of about 90 gsm to about 110 gsm.
10. A thermal acoustic insulation system comprising at least one
insulating layer disposed within a covering of an exteriorly facing
fire barrier laminate as in claim 1, and an interiorly facing
inboard cover film.
11. The system of claim 10, wherein the interiorly facing cover
film consists essentially of a polymer film.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 15/198,910 filed on Jun. 30, 2016, which is a
continuation of U.S. patent application Ser. No. 13/707,999 filed
on Dec. 7, 2012 (now abandoned), which is a division of U.S. patent
application Ser. No. 13/299,399 filed on Nov. 18, 2011 (now
abandoned), which claims the benefit of the filing date under 35
U.S.C. .sctn. 119(e) from U.S. Provisional Patent Application No.
61/415,552 filed on Nov. 19, 2010.
BACKGROUND
[0002] A fire barrier laminate is provided for use in thermal and
acoustical insulation systems, such as, but not limited to, those
used in commercial aircraft.
[0003] The Federal Aviation Administration (FAA) has promulgated
regulations, contained in 14 C.F.R. .sctn. 25.856(a) and (b),
requiring thermal and acoustical insulation blanket systems in
commercial aircraft to provide improved burn through protection and
flame propagation resistance. These conventional thermal and
acoustical insulation systems typically include thermal and
acoustical insulation blankets encapsulated within a film covering
or bag. As the thermal and acoustical insulation systems are
conventionally 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. Conventional film coverings
typically are used as a layer or covering, for example, 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1A is a schematic cross-sectional view of a thermal and
acoustical aircraft insulation blanket protected by an embodiment
of the subject fire barrier laminate.
[0005] FIG. 1B is an exploded cross-sectional view of an
illustrative embodiment of the subject fire barrier laminate
circled portion B' of the embodiment of FIG. 1A.
[0006] FIG. 1C is an exploded cross-sectional view of another
illustrative embodiment of the subject fire barrier laminate
circled portion B' of the embodiment of FIG. 1A.
[0007] FIG. 1D is an exploded cross-sectional view of a further
illustrative embodiment of the subject fire barrier laminate
circled portion B' of the embodiment of FIG. 1A.
[0008] FIG. 1E is an exploded cross-sectional view of a further
illustrative embodiment of the subject fire barrier laminate
circled portion B' of the embodiment of FIG. 1A.
DETAILED DESCRIPTION
[0009] A fire barrier layer is provided which is incorporated into
a fire barrier laminate for use in thermal and acoustical
insulation systems, such as, but not limited to, those used in
commercial aircraft. By way of example, but not limitation, the
fire barrier laminate may be used as a covering that is located
between insulation material in fuselage wall cavities and the outer
skin of an aircraft fuselage (as an outboard cover of an insulation
system) and/or between insulation material in fuselage wall
cavities and the interior aircraft trim panels (as an inboard cover
of an insulation system).
[0010] The incorporation of the subject fire barrier layer in a
fire barrier laminate, used for protecting thermal and acoustical
insulation structures, solves problems previously associated with
the use of lightweight ceramic or inorganic papers, which tend to
be fragile to handling or in use where harsh mechanical
environments are encountered.
[0011] In certain embodiments, the subject fire barrier film
laminate comprises at least one non-fibrous fire barrier layer
coated onto at least one film layer, optionally a water-repellant
material incorporated into and/or applied to the fire barrier
layer, at least one scrim layer, at least one second film layer,
and optionally at least one adhesive layer, the non-fibrous fire
barrier layer comprising at least one inorganic platelet material,
optionally at least one organic binder and/or inorganic binder, and
optionally at least one functional filler.
[0012] In certain embodiments, the fire barrier laminate comprises:
at least one non-fibrous fire barrier layer directly or indirectly
coated onto at least one first polymeric flame propagation
resistant film layer; at least one second film layer proximate to
the non-fibrous fire barrier layer opposite the first polymeric
flame propagation resistant film layer; at least one scrim layer
disposed: (i) between the non-fibrous fire barrier layer and the
first polymeric flame propagation resistant film layer; and/or (ii)
between the non-fibrous fire barrier layer and the second film
layer; and/or (iii) proximate to the first polymeric flame
propagation resistant film layer opposite the non-fibrous fire
barrier layer; and/or (iv) proximate to the second film layer
opposite the non-fibrous fire barrier layer; optionally, a
water-repellant material incorporated into and/or applied to the
non-fibrous fire barrier layer; optionally at least one adhesive
layer adhering the non-fibrous fire barrier layer to the first
polymeric flame propagation resistant film layer; and optionally at
least one adhesive layer adhering the scrim layer to at least one
of the non-fibrous fire barrier layer, the first polymeric flame
propagation resistant film layer, or the second film layer; wherein
the non-fibrous fire barrier layer comprises at least one inorganic
platelet material, optionally at least one organic binder and/or
inorganic binder, and optionally at least one functional filler.
Optionally, the second film layer may also be flame propagation
resistant.
[0013] By indirectly coating, it is meant that the non-fibrous fire
barrier layer may be coated onto an intermediate layer, such as a
scrim, wherein the intermediate layer is engaged with the first
polymeric flame propagation resistant film layer. The intermediate
layer may be engaged with the first polymeric flame propagation
resistant film layer before or after being coated with the
non-fibrous fire barrier layer.
[0014] This composition provides a light basis weight article with
surprising resistance to damage associated with handling and use
along with the ability to resist flame propagation and flame
penetration as defined in 14 C.F.R. .sctn. 25.856(a) and (b). The
term "basis weight" is defined as the weight per unit area,
typically defined in grams per square meter (gsm). The subject fire
barrier layer, and the laminate incorporating it, are therefore
useful in providing fire burn-through protection for thermal and
acoustical insulation structures, referred to in the industry as
"blankets", for commercial aircraft fuselages, as the subject fire
barrier laminate may have a basis weight of between about 80 gsm to
about 120 gsm, and in certain embodiments between about 90 gsm to
about 110 gsm.
[0015] The inorganic platelet material of the fire barrier layer
may comprise at least one of vermiculite, mica, clay or talc. While
any size inorganic platelet material may be used, inorganic
platelet materials with larger relative diameters and high diameter
to thickness aspect ratios may be desirable due to their increased
flame propagation and/or burnthrough resistance performance, as
well as other properties such as flexibility and processability. In
certain embodiments, the inorganic platelet material may have a
diameter of from about 20 .mu.m to about 300 .mu.m. In further
embodiments, the inorganic platelet material may have a diameter of
from about 40 .mu.m to about 200 .mu.m. In certain embodiments, the
inorganic platelet material may have an aspect ratio of from about
50:1 to about 2000:1. In certain embodiments, the inorganic
platelet material may have an aspect ratio of from about 50:1 to
about 1000:1. In further embodiments, the inorganic platelet
material may have an aspect ratio of from about 200:1 to about
800:1.
[0016] The vermiculite or mica may be exfoliated and may further be
defoliated. By exfoliation, it is meant that the vermiculite or
mica is chemically or thermally expanded. By defoliation, it is
meant that the exfoliated vermiculite or mica is processed in order
to reduce the vermiculite or mica to substantially a platelet form.
Vermiculite may be included in the fire barrier layer in an amount
from about 20 to about 100 weight percent, based on the total
weight of the fire barrier layer.
[0017] Suitable micas may include, without limitation, muscovite,
phlogopite, biotite, lepidolite, glauconite, paragonite and
zinnwaldite, and may include synthetic micas such as
fluorophlogopite. Mica may be included in the fire barrier layer in
an amount from about 20 to about 100 weight percent, based on the
total weight of the fire barrier layer.
[0018] Suitable platelet clay materials that may be included in the
fire barrier layer include, without limitation, ball clay,
bentonite, smectite, hectorite, kaolinite, montmorillonite,
saponite, sepiolite, sauconite, or combinations thereof. Platelet
clay materials may be included in the fire barrier layer in an
amount from about 5 to about 60 weight percent, in certain
embodiments from about 5 to about 50 weight percent, based on the
total weight of the fire barrier layer.
[0019] The mica, vermiculite and/or clay platelet materials may
also be combined with further platelet materials, such as talc. If
present, talc may be included in the fire barrier layer in an
amount from about 1 to about 50 weight percent, in certain
embodiments, from about 10 to about 30 weight percent, based on the
total weight of the fire barrier layer.
[0020] The fire barrier layer may include inorganic binders.
Without limitation, suitable inorganic binders include colloidal
dispersions of alumina, silica, zirconia, and mixtures thereof. The
inorganic binders, if present, may be used in amounts ranging from
0 to about 40 percent by weight, in some embodiments from 0 to
about 20 weight percent, based upon the total weight of the fire
barrier layer.
[0021] The fire barrier layer may further include one or more
organic binders. The organic binder(s) may be provided as a solid,
a liquid, a solution, a dispersion, a latex, or similar form.
Examples of suitable organic binders include, but are not limited
to, acrylic latex,(meth)acrylic latex, phenolic resins, copolymers
of styrene and butadiene, vinylpyridine, acrylonitrile, copolymers
of acrylonitrile and styrene, vinyl chloride, polyurethane,
copolymers of vinyl acetate and ethylene, polyamides, organic
silicones, organofunctional silanes, unsaturated polyesters, epoxy
resins, polyvinyl esters (such as polyvinylacetate or
polyvinylbutyrate latexes) and the like.
[0022] The organic binder, if present, may be included in the fire
barrier layer in an amount of from 0 to about 40 weight percent, in
some embodiments from 0 to about 20 weight percent, based upon the
total weight of the fire barrier layer.
[0023] Solvents for the binders, if needed, can include water or a
suitable organic solvent, such as acetone, for the binder utilized.
Solution strength of the binder in the solvent (if used) can be
determined by conventional methods based on the binder loading
desired and the workability of the binder system (viscosity, solids
content, etc.).
[0024] In certain embodiments, the fire barrier layer may comprise
from about 20% to about 100% by weight of the inorganic platelet
material, from 0% to about 40% by weight of the organic binder
and/or inorganic binder, and from 0% to about 50% of the functional
filler.
[0025] In further embodiments, the fire barrier layer may comprise
from about 60% to about 100% by weight of the inorganic platelet
material, from 0% to about 20% by weight of the organic binder
and/or inorganic binder, and from 0% to about 20% of the functional
filler.
[0026] The fire barrier film laminate and/or the fire barrier layer
may additionally comprise a water repellant additive or coating.
The water repellant additive or coating may be a component of the
fire barrier layer or may be a distinct coating or layer within the
fire barrier film laminate or may be saturated or impregnated into
the fire barrier layer. The water repellant additive may
alternatively or additionally be present in the adhesives which may
be utilized in the subject fire barrier laminate. Without
limitation, the water repellant additive or coating may comprise a
water repellant silicone; a metal chloride salt such as calcium
chloride, magnesium chloride, sodium chloride, potassium chloride,
or aluminum chloride; silane; fluorinated compounds or
fluorosurfactants such as polytetrafluoroethylene resin; polymeric
wet strength resins such as polyamide resin or
polyamide-epichlorohydrin resin; mixtures thereof, and the
like.
[0027] The functional filler(s) may include, but not be limited to,
non-platelet clays (such as attapulgite, kyanite, palygorskite,
silimanite, or andalucite), fumed silica, boron nitride, cordierite
and the like. According to certain embodiments, the functional
fillers may include finely divided metal oxides, which may comprise
at least one of pyrogenic silicas, arc silicas, low-alkali
precipitated silicas, fumed silica, silicon dioxide aerogels,
aluminum oxides, titania, calcia, magnesia, potassia, and mixtures
thereof.
[0028] In certain embodiments, the functional filler may comprise
endothermic fillers such as alumina trihydrate, magnesium
carbonate, and other hydrated inorganic materials including
cements, hydrated zinc borate, calcium sulfate (gypsum), magnesium
ammonium phosphate, magnesium hydroxide and combinations thereof.
In further embodiments, the functional filler(s) may include
lithium-containing minerals. In still further embodiments, the
functional fillers(s) may include fluxing agents and/or fusing
agents.
[0029] In certain embodiments, the functional filler may comprise
fire retardant fillers such as antimony compounds, magnesium
hydroxide, hydrated alumina compounds, borates, carbonates,
bicarbonates, inorganic halides, phosphates, sulfates, organic
halogens or organic phosphates.
[0030] The fire barrier layer may be directly or indirectly coated
onto a film, for example, without limitation, by roll or reverse
roll coating, gravure or reverse gravure coating, transfer coating,
spray coating, brush coating, dip coating, tape casting, doctor
blading, slot-die coating, or deposition coating. In certain
embodiments, the fire barrier layer is coated onto the film as a
slurry of the ingredients in a solvent, such as water, and is
allowed to dry prior to incorporation into the fire barrier
laminate. The fire barrier layer may be created as a single layer
or coating, thus utilizing a single pass, or may be created by
utilizing multiple passes, layers or coatings. By utilizing
multiple passes, the potential for formation of defects in the fire
barrier layer is reduced. If multiple passes are desired, the
second and possible subsequent passes may be formed onto the first
pass while the first pass is still substantially wet, i.e. prior to
drying, such that the first and subsequent passes are able to form
a single unitary fire barrier layer upon drying.
[0031] When multiple passes, layers or coatings of the fire barrier
layer are utilized, it is possible to vary the amounts of the
ingredients in each pass, layer or coating, such that the passes,
layers or coatings may have different amounts of, for example,
inorganic platelet material. In certain embodiments, at least one
pass, layer or coating having a greater amount of inorganic
platelet material may be present on the "hot face" of the fire
barrier layer. Further, in certain embodiments another pass, layer
or coating may have a greater amount of functional filler in order
to reduce the amount of defects present in the pass, layer or
coating, and may have a greater ability to correct defects present
in a previous pass, layer or coating.
[0032] In certain embodiments, the fire barrier layer may be
directly or indirectly coated onto a first polymeric flame
propagation resistant film, such as but not limited to polyesters,
polyimides, polyetherketones, polyetheretherketones,
polyvinylfluorides, polyamides, polytetrafluoroethylenes, polyaryl
sulfones, polyester amides, polyesterimides, polyethersulfones,
polyphenylene sulfides, ethylene chlorotrifluoroethylene,
combinations thereof, and the like. 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., a polyetheretherketone film sold
under the trade designation APTIV.RTM. by Victrex, plc of
Lancashire, UK, a polyetheretherketone film sold under the trade
designation KETASPIRE.RTM. and an ethylene chlorotrifluoroethylene
film sold under the trade designation HALAR.RTM. by Solvay SA of
Brussels, Belgium, and the like. The first polymeric flame
propagation resistant film may be metalized to minimize moisture
absorption, particularly on the outboard side, but optionally on
the inboard side also.
[0033] In certain embodiments, the first polymeric flame
propagation resistant film and/or the metalized first polymeric
flame propagation resistant film may have an opaque, low-gloss
polymer coating, optionally containing a fire-retardant additive.
The fire-retardant additives may comprise at least one of antimony
compounds, hydrated alumina compounds, borates, carbonates,
bicarbonates, inorganic halides, phosphates, sulfates, organic
halogens or organic phosphates.
[0034] The fire barrier laminate may additionally include an
adhesive on one of the outer surfaces to facilitate thermal or
other energetic bonding of the laminate to companion backside films
as currently practiced in the fabrication of thermal acoustic
insulation blankets to form a covering, bag, or envelope for the
insulation layers. In some embodiments, a partially or
substantially totally encapsulated insulation system is formed.
(Air holes may be employed to accommodate pressure variation during
flight.) In certain embodiments, the adhesive comprises an adhesive
which is activated by the application of ultrasonic or
radiofrequency energy, or the like.
[0035] Optionally, at least one scrim layer may be disposed within
the adhesive or a surface adjacent to an adhesive on at least one
side of, or within, the fire barrier laminate, in order to, for
example, add strength to the laminate, including puncture or tear
resistance. In certain embodiments, a scrim may be disposed between
the at least one non-fibrous fire barrier layer and the first
polymeric flame propagation resistant film layer, such that the
non-fibrous fire barrier layer may be coated indirectly onto the
flame propagation resistant film layer by coating then on-fibrous
fire barrier layer onto the scrim. The scrim may be in the form of
a mesh, and may comprise fiberglass, nylon, polyester (such as
aromatic polyester), aramid (such as para-aramid), or high or
ultra-high molecular weight polyethylene in various embodiments or
may be absent.
[0036] The fire barrier laminate may additionally include
adhesives, internal to the fire barrier laminate, which are
utilized to laminate or otherwise adhere the layers of the fire
barrier laminate to one another. These adhesives may include
thermally-activated or pressure-based adhesives. The adhesives may
comprise at least one of polyester based adhesives or polyvinyl
fluoride-based adhesives, and/or silicone adhesives. In certain
embodiments, the adhesives may contain fire retardant additives.
The fire-retardant additives may comprise at least one of antimony
compounds, hydrated alumina compounds, borates, carbonates,
bicarbonates, inorganic halides, phosphates, sulfates, organic
halogens or organic phosphates.
[0037] As shown in FIG. 1A, an embodiment of a thermal acoustic
insulation system 10, or "blanket", is depicted in cross-section,
in which two insulating layers 14, such as one inch thick MICROLITE
AA.RTM. Premium NR fiberglass insulation (0.42 pcf) (available from
Johns Manville International, Inc.), are disposed within a covering
of an exteriorly facing fire barrier laminate 16, and an interiorly
facing inboard cover film 18 (optionally, a second fire barrier
laminate). The insulating layers 14 may also or alternatively
comprise polyimide foam insulation. The exteriorly facing laminate
16 and the inboard film 18 may be heat sealed with an adhesive 12
to partially or substantially totally envelop or encapsulate the
fiberglass insulation layers. Flames 20, depicting the FAA test
procedures, are shown proximate to the exteriorly facing fire
barrier laminate 16.
[0038] A detail section of an embodiment of the fire barrier
laminate 16, encircled as B' in FIG. 1A is shown in an exploded
cross-sectional view in FIG. 1B. The fire barrier laminate 16 is
constructed by first applying an adhesive 104 to a first polymeric
flame propagation resistant film 106, such as a
polyetheretherketone film. The fire barrier layer 102 is then
coated onto the adhesive 104-coated first polymeric film 106.
Alternatively, the adhesive 104 may be omitted, resulting in the
fire barrier layer 102 being coated directly onto the first
polymeric film 106. The fire barrier layer 102 may comprise a paste
or slurry type material with an amount of water or other solvent
being present in the fire barrier layer 102 as it is being coated
onto the first polymeric film 106. In this instance, the fire
barrier layer 102 is allowed to dry before continued processing.
Optionally, a water-repellant material maybe incorporated in,
coated onto or saturated/impregnated into the fire barrier layer
102.
[0039] Separately, a scrim layer 108, such as a fiberglass or nylon
scrim, is laminated to a second film 110, such as a
polyetheretherketone film, using an adhesive 114. An adhesive 112
is also used to laminate the fire barrier layer 102-coated first
polymeric film 106 to the scrim layer 108. Alternatively, the scrim
layer 108 may be adhered to the fire barrier layer 102 prior to
laminating the scrim layer 108 to the second film 110.
[0040] Optionally, the assembled fire barrier laminate 16 includes
an encapsulating adhesive layer 116 adjacent to the first polymeric
film 106 in order to encapsulate the insulation layers 14 between
the fire barrier laminate 16 and the inboard film 18. Additionally,
or alternatively, the fire barrier laminate 16 may utilize
mechanical fasteners or tapes for encapsulating the insulating
layers 14 between the fire barrier laminate 16 and the inboard film
18.
[0041] A detail section of another embodiment of the fire barrier
laminate 16, encircled as B' in FIG. 1A is shown in an exploded
cross-sectional view in FIG. 1C. The fire barrier laminate 16 is
constructed by first applying an adhesive 204 to a first polymeric
flame propagation resistant film 206, such as an ethylene
chlorotrifluoroethylene film. The fire barrier layer 202 is then
coated onto the adhesive 204-coated first polymeric film 206.
Alternatively, the adhesive 204 may be omitted, resulting in the
fire barrier layer 202 being coated directly onto the first
polymeric film 206. The fire barrier layer 202 may comprise a paste
or slurry type material with an amount of water or other solvent
being present in the fire barrier layer 202 as it is being coated
onto the first polymeric film 206. In this instance, the fire
barrier layer 202 is allowed to dry before continued processing.
Optionally, a water-repellant material may be incorporated in,
coated onto or saturated/impregnated into the fire barrier layer
202.
[0042] A second film 210, such as a metalized polyetheretherketone
film, is laminated to the fire barrier layer 202-coated first
polymeric film 206 using an adhesive 212. The fire barrier laminate
16 includes a scrim layer 208 laminated to the first polymeric film
206 opposite the fire barrier layer 202 via an adhesive layer
216.
[0043] A detail section of a further embodiment of the fire barrier
laminate 16, encircled as B' in FIG. 1A is shown in an exploded
cross-sectional view in FIG. 1D. The fire barrier laminate 16 is
constructed by first applying an adhesive 304 to a first polymeric
flame propagation resistant film 306, such as a metalized
polyetheretherketone film. The fire barrier layer 302 is then
coated onto the adhesive 304-coated first polymeric film 306.
Alternatively, the adhesive 304 maybe omitted, resulting in the
fire barrier layer 302 being coated directly onto the first
polymeric film 306. The fire barrier layer 302 may comprise a paste
or slurry type material with an amount of water or other solvent
being present in the fire barrier layer 302 as it is being coated
onto the first polymeric film 306. In this instance, the fire
barrier layer 302 is allowed to dry before continued processing.
Optionally, a water-repellant material may be incorporated in,
coated onto or saturated/impregnated into the fire barrier layer
302.
[0044] Separately, a scrim layer 308, such as a fiberglass or nylon
scrim, is laminated to a second film 310, such as a
polyetheretherketone film. An adhesive 312 is also used to laminate
the fire barrier layer 302-coated first polymeric film 306 to the
scrim layer 308. Alternatively, the scrim layer 308 may be adhered
to the fire barrier layer 302 prior to laminating the scrim layer
308 to the second film 310.
[0045] The assembled fire barrier laminate 16 may include an
encapsulating adhesive layer 316 adjacent to the first polymeric
film 306 in order to encapsulate the insulation layers 14 between
the fire barrier laminate 16 and the inboard film 18. A second
scrim layer 308a is optionally embedded in the adhesive layer
316.
[0046] A detail section of a further embodiment of the fire barrier
laminate 16, encircled as B' in FIG. 1A is shown in an exploded
cross-sectional view in FIG. 1E. The fire barrier laminate 16 is
constructed by first applying an adhesive 404 to a first polymeric
flame propagation resistant film 406, such as a
polyetheretherketone film. A second scrim layer 408a is optionally
laminated between the adhesive 404 and the first polymeric film
406. The fire barrier layer 402 is then coated onto the adhesive
404-coated first polymeric film 406. Alternatively, the adhesive
404 may be omitted, resulting in the fire barrier layer 402 being
coated directly onto the first polymeric film 406. The fire barrier
layer 402 may comprise a paste or slurry type material with an
amount of water or other solvent being present in the fire barrier
layer 402 as it is being coated onto the first polymeric film 406.
In this instance, the fire barrier layer 402 is allowed to dry
before continued processing. Optionally, a water-repellant material
maybe incorporated in, coated onto or saturated/impregnated into
the fire barrier layer 402.
[0047] A second film 410, such as a metalized polyetheretherketone
film, is laminated to the fire barrier layer 402-coated first
polymeric film 406 using an adhesive 412. The fire barrier laminate
16 includes a scrim layer 408 laminated to the first polymeric film
406 opposite the fire barrier layer 402 via an adhesive layer
416.
[0048] The following examples are set forth merely to further
illustrate the subject fire barrier layer and fire barrier film
laminate. The illustrative examples should not be construed as
limiting the fire barrier layer and/or fire barrier laminate in any
manner.
[0049] Sample 1 comprised a fire barrier layer containing suspended
exfoliated vermiculite flakes, silicone binder and water. The fire
barrier layer was applied to a polyetheretherketone (PEEK) film
which had previously been coated with a silicone adhesive and
allowed to dry.
[0050] Separately, a second PEEK film was laminated to a nylon
scrim using a silicone laminating adhesive. The scrim side of the
laminate was laminated to the fire barrier layer side of the fire
barrier layer-coated PEEK film to form a fire barrier laminate. A
heat seal adhesive was then applied to the face of the fire barrier
laminate opposite the second PEEK film. The fire barrier laminate
final construction had a basis weight of 97 gsm and passed the test
protocols of 14 C.F.R. .sctn. 25.856(a) and(b), described
below.
[0051] Sample 2 comprised a fire barrier layer containing suspended
exfoliated vermiculite flakes and water. The fire barrier layer was
applied to a polyetheretherketone (PEEK) film which had previously
been coated with a modified natural rubber adhesive and allowed to
dry. Separately, a second PEEK film was laminated to a nylon scrim
using a poly(amide) laminating adhesive. The scrim side of the
laminate was laminated to the fire barrier layer side of the fire
barrier layer-coated PEEK film to form a fire barrier laminate. A
heat seal adhesive was then applied to the face of the fire barrier
laminate opposite the second PEEK film and a fiberglass scrim was
incorporated onto the heat seal adhesive-coated face. The fire
barrier laminate final construction had a basis weight of 90 gsm
and passed the test protocols of 14 C.F.R. .sctn. 25.856(a) and
(b), described below.
[0052] Sample 3 comprised a fire barrier layer containing suspended
exfoliated vermiculite flakes, silicone binder and water. The fire
barrier layer was applied to a polyetheretherketone (PEEK) film
which had previously been coated with a modified natural rubber
adhesive and allowed to dry. Separately, a second PEEK film was
laminated to a nylon scrim using a poly(amide) laminating adhesive.
The scrim side of the laminate was laminated to the fire barrier
layer side of the fire barrier layer-coated PEEK film to form a
fire barrier laminate. A heat seal adhesive was then applied to the
face of the fire barrier laminate opposite the second PEEK film.
The fire barrier laminate final construction had a basis weight of
103 gsm and passed the test protocols of 14 C.F.R. .sctn. 25.856(a)
and (b), described below.
[0053] Sample 4 comprised a fire barrier layer containing suspended
exfoliated vermiculite flakes, silicone binder and water. The fire
barrier layer was applied to a polyetheretherketone (PEEK) film
which had previously been coated with a modified natural rubber
adhesive and allowed to dry. Separately, an ethylene
chlorotrifluoroethylene (ECTFE)film was laminated to a nylon scrim
using a silicone laminating adhesive. The scrim side of the
laminate was laminated to the fire barrier layer side of the fire
barrier layer-coated PEEK film to form a fire barrier laminate. A
heat seal adhesive was then applied to the external face of the
ECTFE film. The fire barrier laminate final construction had a
basis weight of 95 gsm and passed the test protocols of 14 C.F.R.
.sctn. 25.856(a) and (b), described below.
[0054] Sample 5 comprised a fire barrier layer containing suspended
exfoliated vermiculite flakes and water. The fire barrier layer was
applied to a polyetheretherketone (PEEK) film which had previously
been coated with a modified natural rubber adhesive and allowed to
dry. Separately, a second PEEK film was laminated to a nylon scrim
using a silicone laminating adhesive. The scrim side of the
laminate was laminated to the fire barrier layer side of the fire
barrier layer-coated PEEK film to form a fire barrier laminate. A
heat seal adhesive was then applied to the face of the fire barrier
laminate opposite the second PEEK film and a nylon scrim was
incorporated onto the heat seal adhesive-coated face. The fire
barrier laminate final construction had a basis weight of 105 gsm
and passed the test protocols of 14 C.F.R. .sctn. 25.856(a) and
(b), described below.
[0055] For testing according to 14 C.F.R. .sctn. 25.856(a), the
fire barrier laminate of each of the Samples 1-5 was used to
encapsulate two (2) 1-inch layers of 0.34 pcf MICROLITE AA.RTM.
premium fiberglass insulation with LAMAGUARD.RTM. 131MD companion
polymer film. The fire barrier laminate was heat sealed in order to
encapsulate the fiberglass insulation.
[0056] For testing according to 14 C.F.R. .sctn. 25.856(b) the fire
barrier laminate of each of the Samples 1-5 was used to encapsulate
one (1) 1-inch layer of 0.34 pcf MICROLITE AA.RTM. premium
fiberglass insulation with LAMAGUARD.RTM. 131MD companion polymer
film. The fire barrier laminate was mechanically sealed using
staples in order to encapsulate the fiberglass insulation.
Test Protocols
[0057] The fire barrier film laminate-protected thermal/acoustic
insulation blankets described above were tested according to the
protocols of 14 C.F.R. .sctn. 25.856(a) and (b), Appendix F, Parts
VI and VII, which are incorporated herein in their entirety, as if
fully written out below.
[0058] 14 C.F.R. .sctn. 25.856(a) and (b) provide in pertinent
part:
[0059] Table 2
.sctn. 25.856 Thermal/Acoustic Insulation Materials.
[0060] (a)Thermal/acoustic insulation material installed in the
fuselage must meet the flame propagation test requirements of part
VI of Appendix F to this part, or other approved equivalent test
requirements.
[0061] (b) For airplanes with a passenger capacity of 20 or
greater, thermal/acoustic insulation materials (including the means
of fastening the materials to the fuselage) installed in the lower
half of the airplane fuselage must meet the flame penetration
resistance test requirements of part VII of Appendix F to this
part, or other approved equivalent test requirements.
[0062] Appendix F Part VI provides, in pertinent part:
[0063] Table 3
[0064] Part VI--Test Method to Determine the Flammability and Flame
Propagation Characteristics of Thermal/Acoustic Insulation
Materials
[0065] Use this test method to evaluate the flammability and flame
propagation characteristics of thermal/acoustic insulation when
exposed to both a radiant heat source and a flame.
(a) Definitions.
[0066] "Flame propagation" means the furthest distance of the
propagation of visible flame towards the far end of the test
specimen, measured from the midpoint of the ignition source flame.
Measure this distance after initially applying the ignition source
and before all flame on the test specimen is extinguished. The
measurement is not a determination of burn length made after the
test.
[0067] "Radiant heat source" means an electric or air propane
panel.
[0068] "Thermal/acoustic insulation" means a material or system of
materials used to provide thermal and/or acoustic protection.
Examples include fiberglass or other batting material encapsulated
by a film covering and foams.
[0069] "Zero point" means the point of application of the pilot
burner to the test specimen.
(b) Test Apparatus.
[0070] (4) Pilot Burner. The pilot burner used to ignite the
specimen must be a Bernzomatic.TM. commercial propane venturi torch
with an axially symmetric burner tip and a propane supply tube with
an orifice diameter of 0.006 inches (0.15 mm). The length of the
burner tube must be 27/8 inches (71 mm). The propane flow must be
adjusted via gas pressure through an in-line regulator to produce a
blue inner cone length of 3/4 inch (19 mm). A 3/4-inch (19 mm)
guide (such as a thin strip of metal) may be soldered to the top of
the burner to aid in setting the flame height. The overall flame
length must be approximately 5 inches long (127 mm). Provide a way
to move the burner out of the ignition position so that the flame
is horizontal and at least 2 inches (50 mm) above the specimen
plane. (5) Thermocouples. Install a 24 American Wire Gauge (AWG)
Type K (Chromel-Alumel) thermocouple in the test chamber for
temperature monitoring. Insert it into the chamber through a small
hole drilled through the back of the chamber. Place the
thermocouple so that it extends 11 inches (279 mm) out from the
back of the chamber wall, 111/2 inches (292 mm) from the right side
of the chamber wall and is 2 inches (51 mm) below the radiant
panel. The use of other thermocouples is optional.
[0071] (6) Calorimeter. The calorimeter must be a one-inch
cylindrical water-cooled, total heat flux density, foil type Gardon
Gage that has a range of 0 to 5 BTU/ft.sup.2-second (0 to 5.7
Watts/cm.sup.2).
(c) Test Specimens.
[0072] (1) Specimen preparation. Prepare and test a minimum of
three test specimens. If an oriented film cover material is used,
prepare and test both the warp and fill directions.
[0073] (2) Construction. Test specimens must include all materials
used in construction of the insulation (including batting, film,
scrim, tape etc.). Cut a piece of core material such as foam or
fiberglass and cut a piece of film cover material (if used) large
enough to cover the core material. Heat sealing is the preferred
method of preparing fiberglass samples, since they can be made
without compressing the fiberglass ("box sample"). Cover materials
that are not heat sealable may be stapled, sewn, or taped as long
as the cover material is over-cut enough to be drawn down the sides
without compressing the core material. The fastening means should
be as continuous as possible along the length of the seams. The
specimen thickness must be of the same thickness as installed in
the airplane.
[0074] (3) Specimen Dimensions. To facilitate proper placement of
specimens in the sliding platform housing, cut non-rigid core
materials, such as fiberglass, 121/2 inches (318 mm) wide by 23
inches (584 mm) long. Cut rigid materials, such as foam,
111/2.+-.1/4 inches (292 mm.+-.6 mm) wide by 23 inches (584 mm)
long in order to fit properly in the sliding platform housing and
provide a flat, exposed surface equal to the opening in the
housing.
[0075] (d) Specimen conditioning. Condition the test specimens at
70.+-.5.degree. F. (21.degree..+-.2.degree. C.) and 55%..+-.10%
relative humidity, for a minimum of 24 hours prior to testing.
(f) Test Procedure.
[0076] (1) Ignite the pilot burner. Ensure that it is at least 2
inches (51 mm) above the top of the platform. The burner must not
contact the specimen until the test begins.
[0077] (2) Place the test specimen in the sliding platform holder.
Ensure that the test sample surface is level with the top of the
platform. At "zero" point, the specimen surface must be ( 71/2
inches.+-.1/8 inch (191 mm.+-.3) below the radiant panel.
[0078] (3) Place the retaining/securing frame over the test
specimen. It may be necessary (due to compression) to adjust the
sample (up or down) in order to maintain the distance from the
sample to the radiant panel ( 71/2 inches.+-.1/8 inch (191 mm.+-.3)
at "zero" position). With film/fiberglass assemblies, it is
critical to make a slit in the film cover to purge any air inside.
This allows the operator to maintain the proper test specimen
position (level with the top of the platform) and to allow
ventilation of gases during testing. A longitudinal slit,
approximately 2 inches (51 mm) in length, must be centered 3
inches.+-.1/2 inch (76 mm.+-.13 mm) from the left flange of the
securing frame. A utility knife is acceptable for slitting the film
cover.
[0079] (4) Immediately push the sliding platform into the chamber
and close the bottom door.
[0080] (5) Bring the pilot burner flame into contact with the
center of the specimen at the "zero" point and simultaneously start
the timer. The pilot burner must be at a 27.degree. angle with the
sample and be approximately 1/2 inch (12 mm) above the sample. A
stop . . . allows the operator to position the burner correctly
each time.
[0081] (6) Leave the burner in position for 15 seconds and then
remove to a position at least 2 inches (51 mm) above the
specimen.
(g) Report.
[0082] (1) Identify and describe the test specimen.
[0083] (2) Report any shrinkage or melting of the test
specimen.
[0084] (3) Report the flame propagation distance. If this distance
is less than 2 inches, report this as a pass (no measurement
required).
[0085] (4) Report the after-flame time.
(h) Requirements.
[0086] (1) There must be no flame propagation beyond 2 inches (51
mm) to the left of the centerline of the pilot flame
application.
[0087] (2) The flame time after removal of the pilot burner may not
exceed 3 seconds on any specimen.
[0088] Appendix F Part VII provides, in pertinent part:
[0089] Table 4
Part VII--Test Method to Determine the Burnthrough Resistance of
Thermal/Acoustic Insulation Materials
[0090] Use the following test method to evaluate the burnthrough
resistance characteristics of aircraft thermal/acoustic insulation
materials when exposed to a high intensity open flame.
(a) Definitions.
[0091] Burnthrough time means the time, in seconds, for the burner
flame to penetrate the test specimen, and/or the time required for
the heat flux to reach 2.0 Btu/ft.sup.2-sec (2.27 W/cm.sup.2) on
the inboard side, at a distance of 12 inches (30.5 cm) from the
front surface of the insulation blanket test frame, whichever is
sooner. The burnthrough time is measured at the inboard side of
each of the insulation blanket specimens. Insulation blanket
specimen means one of two specimens positioned in either side of
the test rig, at an angle of 30.degree. with respect to vertical.
Specimen set means two insulation blanket specimens. Both specimens
must represent the same production insulation blanket construction
and materials, proportioned to correspond to the specimen size.
(b) Apparatus.
[0092] (3) Calibration rig and equipment.
[0093] (i) Construct individual calibration rigs to incorporate a
calorimeter and thermocouple rake for the measurement of heat flux
and temperature. Position the calibration rigs to allow movement of
the burner from the test rig position to either the heat flux or
temperature position with minimal difficulty.
[0094] (ii) Calorimeter. The calorimeter must be a total heat flux,
foil type Gardon Gage of an appropriate range such as 0-20
Btu/ft.sup.2-sec (0-22.7 W/cm.sup.2), accurate to .+-.3% of the
indicated reading. The heat flux calibration method must be in
accordance with paragraph VI(b)(7) of this appendix.
[0095] (iv) Thermocouples. Provide seven 1/8-inch (3.2 mm) ceramic
packed, metal sheathed, type K (Chromel-Alumel), grounded junction
thermocouples with a nominal 24 American Wire Gauge (AWG) size
conductor for calibration. Attach the thermocouples to a steel
angle bracket to form a thermocouple rake for placement in the
calibration rig during burner calibration.
[0096] (5) Backface calorimeters. Mount two total heat flux Gardon
type calorimeters behind the insulation test specimens on the back
side (cold) area of the test specimen mounting frame. Position the
calorimeters along the same plane as the burner cone centerline, at
a distance of 4 inches (102 mm) from the vertical centerline of the
test frame.
[0097] (i) The calorimeters must be a total heat flux, foil type
Gardon Gage of an appropriate range such as 0-5 Btu/ft.sup.2-sec
(0-5.7 W/cm.sup.2), accurate to .+-.3% of the indicated reading.
The heat flux calibration method must comply with paragraph
VI(b)(7) of this appendix.
[0098] (6) Instrumentation. Provide a recording potentiometer or
other suitable calibrated instrument with an appropriate range to
measure and record the outputs of the calorimeter and the
thermocouples.
[0099] (7) Timing device. Provide a stopwatch or other device,
accurate to .+-.1%, to measure the time of application of the
burner flame and burnthrough time.
(c) Test Specimens.
[0100] (1) Specimen preparation. Prepare a minimum of three
specimen sets of the same construction and configuration for
testing.
[0101] (2) Insulation blanket test specimen.
[0102] (i) For batt-type materials such as fiberglass, the
constructed, finished blanket specimen assemblies must be 32 inches
wide by 36 inches long (81.3 by 91.4 cm), exclusive of heat sealed
film edges.
[0103] (3) Construction. Make each of the specimens tested using
the principal components (i.e., insulation, fire barrier material
if used, and moisture barrier film) and assembly processes
(representative seams and closures).
[0104] (i) Fire barrier material. If the insulation blanket is
constructed with a fire barrier material, place the fire barrier
material in a manner reflective of the installed arrangement. For
example, if the material will be placed on the outboard side of the
insulation material, inside the moisture film, place it the same
way in the test specimen.
[0105] (v) Conditioning. Condition the specimens at 70.degree.
.+-.5.degree. F. (21.degree. .+-.2.degree. C.) and 55%. .+-.10%
relative humidity for a minimum of 24 hours prior to testing.
(f) Test Procedure.
[0106] (1) Secure the two insulation blanket test specimens to the
test frame. The insulation blankets should be attached to the test
rig center vertical former using four spring clamps . . .
(according to the criteria of paragraph (c)(4) or (c)(4)(i) of this
part of this appendix).
[0107] (2) Ensure that the vertical plane of the burner cone is at
a distance of 4.+-.0.125 inch (102.+-.3 mm) from the outer surface
of the horizontal stringers of the test specimen frame, and that
the burner and test frame are both situated at a 30.degree. angle
with respect to vertical.
[0108] (3) When ready to begin the test, direct the burner away
from the test position to the warm-up position so that the flame
will not impinge on the specimens prematurely. Turn on and light
the burner and allow it to stabilize for 2 minutes.
[0109] (4) To begin the test, rotate the burner into the test
position and simultaneously start the timing device.
[0110] (5) Expose the test specimens to the burner flame for 4
minutes and then turn off the burner. Immediately rotate the burner
out of the test position.
[0111] (6) Determine (where applicable) the burnthrough time, or
the point at which the heat flux exceeds 2.0 Btu/ft.sup.2-sec (2.27
W/cm.sup.2).
(g) Report.
[0112] (1) Identify and describe the specimen being tested.
[0113] (2) Report the number of insulation blanket specimens
tested.
[0114] (3) Report the burnthrough time (if any), and the maximum
heat flux on the back face of the insulation blanket test specimen,
and the time at which the maximum occurred.
(h) Requirements.
[0115] (1) Each of the two insulation blanket test specimens must
not allow fire or flame penetration in less than 4 minutes.
[0116] (2) Each of the two insulation blanket test specimens must
not allow more than 2.0 Btu/ft.sup.2-sec (2.27 W/cm.sup.2) on the
cold side of the insulation specimens at a point 12 inches (30.5
cm) from the face of the test rig.
[0117] In a first embodiment, a subject fire barrier laminate may
comprise: at least one non-fibrous fire barrier layer directly or
indirectly coated onto at least one first polymeric flame
propagation resistant film layer; at least one second film layer
proximate to the non-fibrous fire barrier layer opposite the first
polymeric flame propagation resistant film layer; at least one
scrim layer disposed: (i) between the non-fibrous fire barrier
layer and the first polymeric flame propagation resistant film
layer; and/or (ii) between the non-fibrous fire barrier layer and
the second film layer; and/or (iii) proximate to the first
polymeric flame propagation resistant film layer opposite the
non-fibrous fire barrier layer; and/or (iv) proximate to the second
film layer opposite the non-fibrous fire barrier layer; optionally,
a water-repellant material incorporated into and/or applied to the
non-fibrous fire barrier layer; optionally at least one adhesive
layer adhering the non-fibrous fire barrier layer to the first
polymeric flame propagation resistant film layer; and optionally at
least one adhesive layer adhering the scrim layer to at least one
of the non-fibrous fire barrier layer, the first polymeric flame
propagation resistant film layer, or the second film layer; wherein
the non-fibrous fire barrier layer comprises at least one inorganic
platelet material, optionally at least one organic binder and/or
inorganic binder, and optionally at least one functional
filler.
[0118] The fire barrier laminate of the first embodiment may
further include that the inorganic platelet material comprises at
least one of vermiculite, mica, clay or talc. The vermiculite may
be exfoliated and optionally defoliated. The clay may comprise at
least one of ball clay, bentonite, smectite, hectorite, kaolinite,
montmorillonite, saponite, sepiolite or sauconite.
[0119] The fire barrier laminate of either or both of the first or
subsequent embodiments may further include that the organic binder
comprises at least one of acrylic latex, (meth)acrylic latex,
phenolic resins, copolymers of styrene and butadiene,
vinylpyridine, acrylonitrile, copolymers of acrylonitrile and
styrene, vinyl chloride, polyurethane, copolymers of vinyl acetate
and ethylene, polyamides, silicones, unsaturated polyesters, epoxy
resins or polyvinyl esters.
[0120] The fire barrier laminate of any of the first or subsequent
embodiments may further include that the inorganic binder comprises
at least one of colloidal alumina, colloidal silica or colloidal
zirconia.
[0121] The fire barrier laminate of any of the first or subsequent
embodiments may further include that the non-fibrous fire barrier
layer comprises from about 20% to about 100% by weight of the
inorganic platelet material, from 0% to about 40% by weight of the
organic binder and/or inorganic binder, and from 0% to about 50% of
the functional filler.
[0122] The fire barrier laminate of any of the first or subsequent
embodiments may further include that the non-fibrous fire barrier
layer comprises from about 60% to about 100% by weight of the
inorganic platelet material, from 0% to about 20% by weight of the
organic binder and/or inorganic binder, and from 0% to about 20% of
the functional filler.
[0123] The fire barrier laminate of any of the first or subsequent
embodiments may further include that either or both of the first
polymeric flame propagation resistant film layer or the second film
layer comprises at least one of polyesters, polyimides,
polyetherketones, polyetheretherketones, polyvinylfluorides,
polyamides, polytetrafluoroethylenes, polyaryl sulfones, polyester
amides, polyesterimides, polyethersulfones, polyphenylene sulfides,
ethylene chlorotrifluoroethylene, or combinations thereof.
[0124] The fire barrier laminate of any of the first or subsequent
embodiments may further include that the at least one scrim layer
comprises at least one of fiberglass, nylon, polyester, aramid, or
high or ultra-high molecular weight polyethylene.
[0125] The fire barrier laminate of any of the first or subsequent
embodiments may further include that either or both of the first
polymeric flame propagation resistant film layer and the second
film layer are metalized. Either or both of the first polymeric
flame propagation resistant film layer or the second film layer
have an opaque, low-gloss polymer coating, optionally including a
fire-retardant additive.
[0126] The fire barrier laminate of any of the first or subsequent
embodiments may have a basis weight of less than about 120 gsm.
[0127] In a second embodiment, a subject thermal acoustic
insulation system may comprise a plurality of insulating layers
disposed within a covering of an exteriorly facing fire barrier
laminate as in any of the first or subsequent embodiments, and an
interiorly facing inboard cover film.
[0128] The thermal acoustic insulation system of the second
embodiment may further include that the interiorly facing cover
film also comprises the fire barrier laminate.
[0129] The thermal acoustic insulation system of either or both of
the second or subsequent embodiments may further include that the
exteriorly facing fire barrier laminate and the interiorly facing
inboard cover film are sealed with an adhesive to partially or
substantially totally envelop or encapsulate the plurality of
insulating layers.
[0130] The thermal acoustic insulation system of any of the second
or subsequent embodiments may further include that the insulating
layers comprise fiberglass insulation and/or polyimide foam
insulation.
[0131] The thermal acoustic insulation system of any of the second
or subsequent embodiments may be capable of passing the flame
propagation and burn-through resistance test protocols of 14 C.F.R.
.sctn. 25.856(a)and (b), Appendix F, Parts VI and VII.
[0132] In a third embodiment, a subject method of making a fire
barrier laminate may comprise: directly or indirectly coating at
least one non-fibrous fire barrier layer onto a first polymeric
flame propagation resistant film layer; laminating the non-fibrous
fire barrier layer with at least one second film layer, wherein the
second film layer is proximate to the non-fibrous fire barrier
layer; and laminating at least one scrim layer within the fire
barrier laminate, wherein the at least one scrim layer is disposed:
(i) between the non-fibrous fire barrier layer and the first
polymeric flame propagation resistant film layer; and/or (ii)
between the non-fibrous fire barrier layer and the second film
layer; and/or (iii) proximate to the first polymeric flame
propagation resistant film layer opposite the non-fibrous fire
barrier layer; and/or (iv) proximate to the second film layer
opposite the non-fibrous fire barrier layer; wherein the
non-fibrous fire barrier layer comprises at least one inorganic
platelet material, optionally at least one organic binder and/or
inorganic binder, and optionally at least one functional filler;
and wherein the non-fibrous fire barrier layer optionally contains
a water repellant material, and/or the method further comprises
optionally coating and/or saturating the non-fibrous fire barrier
layer with a water repellant material.
[0133] The method of the third embodiment may further include that
the inorganic platelet material comprises at least one of
vermiculite, mica, clay or talc. The vermiculite may be exfoliated
and optionally defoliated.
[0134] The method of either or both of the third or subsequent
embodiments may further include that the organic binder comprises
at least one of acrylic latex, (meth)acrylic latex, phenolic
resins, copolymers of styrene and butadiene, vinylpyridine,
acrylonitrile, copolymers of acrylonitrile and styrene, vinyl
chloride, polyurethane, copolymers of vinyl acetate and ethylene,
polyamides, silicones, unsaturated polyesters, epoxy resins or
polyvinyl esters.
[0135] The method of any of the third or subsequent embodiments may
further include that the inorganic binder comprises at least one of
colloidal alumina, colloidal silica or colloidal zirconia.
[0136] The method of any of the third or subsequent embodiments may
further include that the non-fibrous fire barrier layer comprises
from about 20% to about 100% by weight of the inorganic platelet
material, from 0% to about 40% by weight of the organic binder
and/or inorganic binder, and from 0% to about 50% of the functional
filler.
[0137] The method of any of the third or subsequent embodiments may
further include that either or both of the first polymeric flame
propagation resistant film layer or the second film layer comprises
at least one of polyesters, polyimides, polyetherketones,
polyetheretherketones, polyvinylfluorides, polyamides,
polytetrafluoroethylenes, polyaryl sulfones, polyester amides,
polyesterimides, polyethersulfones, polyphenylene sulfides,
ethylene chlorotrifluoroethylene, or combinations thereof.
[0138] The method of any of the third or subsequent embodiments may
further include that the at least one scrim layer comprises at
least one of fiberglass, nylon, polyester, aramid, or high or
ultra-high molecular weight polyethylene.
[0139] The method of any of the third or subsequent embodiments may
further include that either or both of the first polymeric flame
propagation resistant film layer or the second film layer are
metalized. Either or both of the first polymeric flame propagation
resistant film layer or the second film layer may be coated with an
opaque, low-gloss polymer, optionally including a fire-retardant
additive.
[0140] It will be understood that the embodiments described herein
are merely illustrative, and that one skilled in the art may make
variations and modifications without departing from the spirit and
scope of the invention. All such variations and modifications are
intended to be included within the scope of the invention as
described hereinabove. Further, all embodiments disclosed are not
necessarily in the alternative, as various embodiments of the
invention may be combined to provide the desired result.
* * * * *