Composite Article Having Excellent Fire Resistance

Abstract

A composite article includes a first pane comprising a first window layer formed from a vitreous material and a reinforced silicone layer disposed adjacent to and in contact with the first window layer. The reinforced silicone layer includes a cured silicone composition and a fiber reinforcement. The composite article includes a second pane spaced from the first pane to define a gap therebetween and a frame disposed adjacent to and in contact with the first pane and the second pane to enclose the gap. The composite article may be suitable for load-bearing applications requiring thermal and acoustic insulation.

1 . A composite article comprising:
 a first pane comprising:
 a first window layer formed from a first vitreous material; and 
 a reinforced silicone layer disposed adjacent to and in contact with said first window layer and comprising a cured silicone composition and a fiber reinforcement; 
   a second pane spaced from said first pane to define a gap therebetween;   a frame disposed adjacent to and in contact with said first pane and said second pane and enclosing the gap between said first pane and said second pane.   
   
   
       2 . (canceled) 
   
   
       3 . (canceled) 
   
   
       4 . A composite article as set forth in  claim 1  wherein said fiber reinforcement is impregnated with said cured silicone composition. 
   
   
       5 . A composite article as set forth in  claim 1  wherein said cured silicone composition is further defined as a hydrosilylation-cured silicone composition comprising the reaction product of:
 (A) a silicone resin; and   (B) an organosilicon compound having an average of at least two silicon-bonded hydrogen atoms per molecule in an amount sufficient to cure said silicone resin;   in the presence of (C) a catalytic amount of a hydrosilylation catalyst.   
   
   
       6 . (canceled) 
   
   
       7 . A composite article as set forth in  claim 1  wherein said cured silicone composition is further defined as a condensation-cured silicone composition comprising the reaction product of:
 (A″) a silicone resin having at least two of a silicon-bonded hydroxy group or a hydrolysable group; and   optionally, (B′) a cross-linking agent having silicon-bonded hydrolysable groups,   optionally, in the presence of (C′) a catalytic amount of a condensation catalyst.   
   
   
       8 . (canceled) 
   
   
       9 . A composite article as set forth in  claim 1  wherein said condensation-cured silicone composition further includes an inorganic filler in particulate form. 
   
   
       10 . A composite article as set forth in  claim 1  wherein said cured silicone composition is further defined as a free radical-cured silicone composition. 
   
   
       11 . A composite article as set forth in  claim 1  wherein said silicone composition includes at least one functional group prior to curing for adhering said cured silicone composition to said first window layer. 
   
   
       12 . A composite article as set forth in  claim 11  wherein said at least one functional group is selected from the group of silanol groups, alkoxy groups, epoxy groups, silicon hydride groups, acetoxy groups, and combinations thereof. 
   
   
       13 . A composite article as set forth in  claim 1  further comprising an adhesive layer disposed between said reinforced silicone layer and said first window layer. 
   
   
       14 . A composite article as set forth in  claim 13  wherein said adhesive layer comprises a silicone-based adhesive. 
   
   
       15 . A composite article as set forth in  claim 1  wherein the gap has a width of from about 1 mm to about 30 mm. 
   
   
       16 . A composite article as set forth in  claim 1  wherein a pressure inside the gap is less than about 0.1 atm. 
   
   
       17 . A composite article as set forth in  claim 1  wherein an insulator is disposed in the gap. 
   
   
       18 . (canceled) 
   
   
       19 . A composite article as set forth in  claim 1  wherein said frame is formed from an adhesive. 
   
   
       20 . A composite article as set forth in  claim 1  wherein said frame is adhered to said first pane and said second pane. 
   
   
       21 . A composite article as set forth in  claim 1  wherein said first pane further comprises an additional window layer disposed adjacent to and in contact with said reinforced silicone layer and opposite said first window layer. 
   
   
       22 . A composite article as set forth in  claim 1  wherein said second pane comprises a second window layer formed from a second vitreous material and a second silicone layer disposed adjacent to and in contact with said second window layer. 
   
   
       23 . A composite article as set forth in  claim 1  further comprising a third pane comprising a third window layer formed from a third vitreous material and a third silicone layer and disposed adjacent to and in contact with said first window layer. 
   
   
       24 . A composite article as set forth in  claim 1  further comprising a third pane comprising a third window layer formed from a third vitreous material and a third silicone layer and spaced from said first pane and said second pane and defining at least one gap therebetween. 
   
   
       25 . A composite article as set forth in  claim 1  wherein said first vitreous material is selected from the group of polymethyl methacrylate, polycarbonate, and polysulfone. 
   
   
       26 . A composite article as set forth in  claim 1  having a fire rating of at least 30 minutes in accordance with at least one of ASTM E 119-05a, ASTM E 2010-01, and ASTM E 2074-00. 
   
   
       27 . A composite article as set forth in  claim 1  further comprising a low E coating disposed on at least one of said panes. 
   
   
       28 . A composite article as set forth in  claim 1  further comprising a low E coating disposed within at least one of said panes.