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 thermal acoustic insulation system that passes the flame propagation and burnthrough resistance test protocols of 14 C.F.R. §25.856(a) and (b), Appendix F, Parts VI and VII, comprising at least one insulating layer disposed within a covering of:
 (i) an exteriorly facing 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 exteriorly facing fire barrier laminate has a basis weight of about 80 gsm to about 120 gsm; and 
 
 (ii) an interiorly facing inboard cover film. 
 
     
     
         2 . The system of  claim 1 , wherein at least one water-repellant material is incorporated into and/or applied to the non-fibrous fire barrier layer. 
     
     
         3 . The system of  claim 1 , wherein the exteriorly facing 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 
     
     
         4 . The system of  claim 1 , wherein the exteriorly facing 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. 
     
     
         5 . The system of  claim 1 , wherein the inorganic platelet material comprises vermiculite which is exfoliated and defoliated. 
     
     
         6 . The system of  claim 1 , wherein the inorganic platelet material comprises mica. 
     
     
         7 . The system of  claim 1 , wherein the inorganic platelet material comprises clay. 
     
     
         8 . The system of  claim 1 , wherein the inorganic platelet material comprises talc. 
     
     
         9 . The system of  claim 1 , wherein the inorganic platelet material comprises clay, wherein the clay comprises at least one of ball clay, bentonite, smectite, hectorite, kaolinite, montmorillonite, saponite, sepiolite or sauconite. 
     
     
         10 . The system of  claim 1 , wherein the non-fibrous fire barrier layer further comprises an organic binder, 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. 
     
     
         11 . The system of  claim 1 , wherein the non-fibrous fire barrier layer further comprises an inorganic binder, wherein the inorganic binder comprises at least one of colloidal alumina, colloidal silica or colloidal zirconia. 
     
     
         12 . The system of  claim 1 , wherein the non-fibrous fire barrier layer further comprises a functional filler. 
     
     
         13 . The system of  claim 12 , wherein the functional filler comprises at least one of non-platelet clays, fumed silica, boron nitride, or cordierite. 
     
     
         14 . The system of  claim 12 , wherein the functional filler comprises at least one of pyrogenic silicas, arc silicas, low-alkali precipitated silicas, fumed silica, silicon dioxide aerogels, aluminum oxides, titania, calcia, magnesia, or potassia. 
     
     
         15 . The system of  claim 12 , wherein the functional filler comprises at least one of alumina trihydrate, magnesium carbonate, cements, hydrated zinc borate, calcium sulfate, magnesium ammonium phosphate, or magnesium hydroxide. 
     
     
         16 . The system of  claim 12 , wherein the functional filler comprises at least one of antimony compounds, magnesium hydroxide, hydrated alumina compounds, borates, carbonates, bicarbonates, inorganic halides, phosphates, sulfates, organic halogens or organic phosphates. 
     
     
         17 . The system 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 an organic binder and/or an inorganic binder, and from 0% to about 50% of a functional filler. 
     
     
         18 . The system 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 an organic binder and/or an inorganic binder, and from 0% to about 20% of a functional filler. 
     
     
         19 . The system 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, or ethylene chlorotrifluoroethylene. 
     
     
         20 . The system 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. 
     
     
         21 . The system of  claim 1 , wherein either or both of the first polymeric flame propagation resistant film layer and the second film layer are metalized. 
     
     
         22 . The system of  claim 1 , 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. 
     
     
         23 . The system of  claim 22 , wherein the opaque, low-gloss polymer coating includes a fire retardant additive. 
     
     
         24 . The system of  claim 1 , wherein the exteriorly facing fire barrier laminate has a basis weight of about 90 gsm to about 110 gsm. 
     
     
         25 . The system of  claim 1 , wherein the interiorly facing cover film consists essentially of a polymer film. 
     
     
         26 . The system of  claim 1 , 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 at least one insulating layer. 
     
     
         27 . The system of  claim 1 , wherein the at least one insulating layer comprises fiberglass insulation and/or polyimide foam insulation. 
     
     
         28 . The system of  claim 1 , wherein the at least one inorganic platelet material comprises particles having an average diameter of from about 20 μm to about 300 μm. 
     
     
         29 . The system of  claim 1 , wherein the at least one inorganic platelet material comprises particles having an average diameter of from about 40 μm to about 200 μm.