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.

1 . A fire barrier laminate comprising:
 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.   
     
     
         2 . The fire barrier laminate of  claim 1 , wherein the inorganic platelet material comprises at least one of vermiculite, mica, clay or talc. 
     
     
         3 . The fire barrier laminate of  claim 2 , wherein the vermiculite is exfoliated and optionally defoliated. 
     
     
         4 . The fire barrier laminate of  claim 2 , wherein the clay comprises at least one of ball clay, bentonite, smectite, hectorite, kaolinite, montmorillonite, saponite, sepiolite or sauconite. 
     
     
         5 . The fire barrier laminate of  claim 1 , wherein 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. 
     
     
         6 . The fire barrier laminate of  claim 1 , wherein the inorganic binder comprises at least one of colloidal alumina, colloidal silica or colloidal zirconia. 
     
     
         7 . The fire barrier laminate of  claim 1 , wherein 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. 
     
     
         8 . The fire barrier laminate of  claim 1 , wherein 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. 
     
     
         9 . The fire barrier laminate of  claim 1 , wherein 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, polyester imides, polyethersulfones, polyphenylene sulfides, ethylene chlorotrifluoroethylene, or combinations thereof. 
     
     
         10 . The fire barrier laminate of  claim 1 , wherein the at least one scrim layer comprises at least one of fiberglass, nylon, polyester, aramid, or high or ultra-high molecular weight polyethylene. 
     
     
         11 . The fire barrier laminate of  claim 1 , wherein either or both of the first polymeric flame propagation resistant film layer and the second film layer are metalized. 
     
     
         12 . The fire barrier laminate of  claim 11 , wherein 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. 
     
     
         13 . The fire barrier laminate of  claim 1  having a basis weight of less than about 120 gsm. 
     
     
         14 . A thermal acoustic insulation system comprising a plurality of insulating layers disposed within a covering of an exteriorly facing fire barrier laminate as in  claim 1 , and an interiorly facing inboard cover film. 
     
     
         15 . The thermal acoustic insulation system of  claim 14 , wherein the interiorly facing cover film also comprises the fire barrier laminate. 
     
     
         16 . The thermal acoustic insulation system of  claim 14 , wherein 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. 
     
     
         17 . The thermal acoustic insulation system of  claim 14 , wherein the insulating layers comprise fiberglass insulation and/or polyimide foam insulation. 
     
     
         18 . The thermal acoustic insulation system of  claim 14  capable of passing the flame propagation and burn-through resistance test protocols of 14 C.F.R. §25.856(a) and (b), Appendix F, Parts VI and VII. 
     
     
         19 . A method of making a fire barrier laminate comprising:
 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 with 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.   
     
     
         20 . The method of  claim 19 , wherein the inorganic platelet material comprises at least one of vermiculite, mica, clay or talc. 
     
     
         21 . The method of  claim 20 , wherein the vermiculite is exfoliated and optionally defoliated. 
     
     
         22 . The method of  claim 19 , wherein 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. 
     
     
         23 . The method of  claim 19 , wherein the inorganic binder comprises at least one of colloidal alumina, colloidal silica or colloidal zirconia. 
     
     
         24 . The method of  claim 19 , wherein 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. 
     
     
         25 . The method of  claim 19 , wherein 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, polyester imides, polyethersulfones, polyphenylene sulfides, ethylene chlorotrifluoroethylene, or combinations thereof. 
     
     
         26 . The method of  claim 19 , wherein the at least one scrim layer comprises at least one of fiberglass, nylon, polyester, aramid, or high or ultra-high molecular weight polyethylene. 
     
     
         27 . The method of  claim 19 , wherein either or both of the first polymeric flame propagation resistant film layer or the second film layer are metalized. 
     
     
         28 . The method of  claim 27 , further comprising coating either or both of the first polymeric flame propagation resistant film layer or the second film layer with an opaque, low-gloss polymer, optionally including a fire retardant additive.