Fire Protective Compositions and Associated Methods

Abstract

Fire protective compositions include colloidal silica solids, clay, a low biopersistence fiber or refractory ceramic fiber, water, and optionally a chelating agent. Methods of using the fire protective compositions include providing a polymeric foam substrate, applying the fire protective composition on the polymeric foam substrate, and allowing the fire protective composition to dry.

What is claimed is: 
     
         1 . A fire-resistant building material, comprising:
 a polymeric insulation board;   a first fire protective coating comprising inorganic fibers, the first fire protective coating being disposed on the polymeric insulation board;   a second fire protective coating comprising inorganic mineral platelets, the second fire protective coating being disposed on the first fire protective coating.   
     
     
         2 . The fire-resistant building material of  claim 1 , wherein the inorganic fibers are selected from rock wool fibers, slag wool fibers, mineral wool fibers, high alumina polycrystalline fibers, refractory ceramic fibers, alumina-magnesia-silica fibers, kaolin fibers, alkaline earth silicate fibers, glass fibers, quartz fibers and silica fibers. 
     
     
         3 . The fire-resistant building material of  claim 2 , wherein the refractory ceramic fibers comprise alumina fibers, alumina-silica fibers, alumina-zirconia-silica fibers, zirconia-silica fibers and zirconia fibers. 
     
     
         4 . The fire-resistant building material of  claim 2 , wherein the alkaline earth silicate fibers are selected from calcia-magnesia-silica fibers and magnesia-silica fibers. 
     
     
         5 . The fire-resistant building material of  claim 2 , wherein the glass fibers are selected from S-glass fibers, S2-glass fibers and E-glass fibers. 
     
     
         6 . The fire-resistant building material of  claim 1 , wherein the first fire protective coating comprises about 75 to about 85 weight percent of the inorganic fibers. 
     
     
         7 . The fire-resistant building material of  claim 1 , wherein the inorganic mineral platelets are selected from vermiculite, mica, clay and talc. 
     
     
         8 . The fire-resistant building material of  claim 1 , wherein the second fire protective coating comprises about 20 to about less than 100 weight percent of the inorganic mineral platelets. 
     
     
         9 . The fire-resistant building material of  claim 1 , wherein at least one of the first and second fire protective coatings comprises an inorganic binder selected from hydraulic cements, non-hydraulic cements and oxychloride cements. 
     
     
         10 . The fire-resistant building material of  claim 9 , wherein the hydraulic cement is selected from Portland cement, masonry cement, alumina cement, refractory cement, calcium aluminate cement, calcium sulfoaluminate cement, ground granulated blast furnace slag, and natural cement. 
     
     
         11 . The fire-resistant building material of  claim 1 , wherein at least one of the first and second fire protective coatings comprises an inorganic binder selected from colloidal alumina, colloidal silica and colloidal zirconia. 
     
     
         12 . The fire-resistant building material of  claim 1 , wherein the second fire protective coating comprises an organic binder selected from 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, phenolics, polyamides, silicones, organic silicones, organofunctional silanes, unsaturated polyesters, epoxy resins, and polyvinyl esters. 
     
     
         13 . The fire-resistant building material of  claim 1 , wherein at least one of the first and second fire protective coatings comprises a thickening agent selected from bentonite, hectorite, kaolinite, montmorillonite, polygorskite, saponite, smectite and sepiolite. 
     
     
         14 . The fire-resistant building material of  claim 1 , wherein at least one of the first and second fire protective coatings comprises a chelating agent selected from diammonium ethylenediamine tetraacetic acid (EDTA), sodium phytate/phytic acid, citric acid/sodium citrate, sodium gluconate, nitrilotriacetic acid, disodium EDTA, disodium ethylenediamine disuccinate, cyclodextrin or diethylenetriaminepentaacetic acid. 
     
     
         15 . The fire-resistant building material of  claim 1 , wherein the polymeric insulation board comprises a polymer foam selected from polystyrene, polyurethane, polyisocyanurate, phenolic, polyurea, low density polyethylene, high density polyethylene, polyvinylchloride, polypropylene, polytetrafluoroethylene, polyamide, polyimide, polyamideimide, polyester, polyetherketone, polyetheretherketone, polyetherketoneketone, polyvinylfluoride, polyaryl sulfone, polyester amide, polyester imide, polyethersulfone, polyphenylene sulfide, ethylene chlorotrifluoroethylene, polyethylene terephthalate, and acrylic polymers. 
     
     
         16 . The fire-resistant building material of  claim 1 , wherein a foil facing is disposed between the polymeric insulation board and the first fire protective coating. 
     
     
         17 . The fire-resistant building material of  claim 16 , wherein the foil facing totally envelops the polymeric insulation board. 
     
     
         18 . The fire-resistant building material of  claim 16 , wherein the foil comprises one or more malleable metals selected from aluminum, copper, zinc, steel and tin. 
     
     
         19 . The fire-resistant building material of  claim 1 , wherein a glass fiber facing is disposed between the polymeric insulation board and the first fire protective coating. 
     
     
         20 . The fire-resistant building material of  claim 19 , wherein the glass fiber facing totally envelops the polymeric insulation board. 
     
     
         21 . The fire-resistant building material of  claim 19 , wherein the glass fiber facing comprises E-glass.