Composite laminate for a thermal and acoustic insulation blanket

Abstract

This invention is directed to a composite laminate comprising in order (a) a flame retardant polymeric moisture barrier (b) an inorganic platelet layer and (c) a flame retardant thermoplastic film layer The invention is also directed to a thermal insulation and acoustic blanket comprising a core of fibrous material or foam surrounded by the above composite laminate wherein the thermoplastic film layer of the composite laminate contacts and encapsulates the core.

What is claimed is: 
     
       1. A thermal insulation and acoustic blanket comprising
 (a) an inorganic or organic core having a self extinguishing time no greater than 10 seconds and a maximum burn length of no greater than 102 mm when tested in accordance with BSS7230 Method F1, 
 (b) a composite laminate surrounding the core material the laminate further comprising
 (1) a polymeric moisture barrier having a thickness from 6.0 to 25.0 micrometers and a UL 94 flame classification of V-0, 
 (2) an a carrier free, inorganic platelet layer having a thickness from 7.0 to 76.0 micrometers and a UL 94 flame classification of V-0 wherein the platelets comprising the platelet layer have an aspect ratio of from 100 to 20,000, and 
 (3) a thermoplastic film layer having a thickness no greater than 25 micrometers, an average elongation to break no greater than 150% and a UL 94 flame classification of V-0, 
 wherein the thermoplastic film layer of the composite laminate contacts and encapsulates the entire core. 
 
 
     
     
       2. The blanket of  claim 1  wherein the core comprises a layer of mineral fiber batting. 
     
     
       3. The blanket of  claim 1  wherein the core comprises polymeric foam. 
     
     
       4. The blanket of  claim 1  wherein the moisture barrier contains a polymer wherein the polymer is selected from the group consisting of fluoropolymer, polyimide, polyetheretherketone and polyetherketoneketone. 
     
     
       5. The blanket of  claim 1  wherein the outer surface of the moisture barrier is metalized. 
     
     
       6. The blanket of  claim 1  wherein the inorganic platelet layer contains platelets selected from the group consisting of clay, vermiculite, mica, talc and combinations thereof. 
     
     
       7. The blanket of  claim 1  wherein wherein the thermoplastic film contains polymer selected from the group consisting of polyketone, polyimide, polysulfone, polyarylene sulfide, fluoropolymer, liquid crystal polymer and polycarbonate. 
     
     
       8. The blanket of  claim 7  wherein the thermoplastic film contains polymer selected from the group consisting of polyetheretherketone, polyetherketoneketone, polyetherimide, polyethersulfone, polyphenylsulfone, poly(p -phenylenesulfide), polyvinylfluoride, polyvinylidinefluoride and polyarylate. 
     
     
       9. A thermal insulation and acoustic blanket, comprising:
 (a) an inorganic or organic core,   (b) a laminate surrounding the core, the laminate comprising
 (1) a polymeric moisture barrier, 
 (2) a carrier free, inorganic platelet layer consisting essentially of platelets of vermiculite, and 
 (3) a thermoplastic film layer, 
   wherein the thermoplastic film layer contacts and encapsulates the entire core.   
     
     
       10. The blanket of claim 9, wherein the core comprises a layer of mineral fiber batting. 
     
     
       11. The blanket of claim 9, wherein the core comprises foam. 
     
     
       12. The blanket of claim 9, wherein the moisture barrier contains polymer selected from the group consisting of fluoropolymer, polyimide, polyetheretherketone and polyetherketoneketone. 
     
     
       13. The blanket of claim 9, wherein the outer surface of the moisture barrier is metalized. 
     
     
       14. The blanket of claim 9, wherein the thermoplastic film layer contains polymer selected from the group consisting of polyketone, polyimide, polysulfone, polyarylene sulfide, fluoropolymer, liquid crystal polymer and polycarbonate. 
     
     
       15. The blanket of claim 9, wherein the thermoplastic film layer contains polymer selected from the group consisting of polyetheretherketone, polyetherketoneketone, polyetherimide, polyethersulfone, polyphenylsulfone, poly(p-phenylenesulfide), polyvinylfluoride, polyvinylidinefluoride and polyarylate. 
     
     
       16. The blanket of claim 9, wherein the carrier free, inorganic platelet layer consists of platelets of vermiculite. 
     
     
       17. The blanket of claim 9, wherein the laminate comprises two of the laminates with one of the laminates on one side of the core and the other laminate on an opposite side of the core with edge portions of the thermoplastic film layers of the two laminates fused together encapsulating the entire core. 
     
     
       18. The blanket of claim 9, wherein the platelets have an aspect ratio of from 100 to 20,000. 
     
     
       19. The blanket of claim 18, wherein the platelets have a thickness of from 5 Angstroms to 5,000 Angstroms. 
     
     
       20. The blanket of claim 9, wherein the thermoplastic film layer of the laminate contacts and encapsulates the entire core. 
     
     
       21. The blanket of claim 9, wherein the inorganic platelet layer has a thickness from 7.0 to 76.0 micrometers. 
     
     
       22. The blanket of claim 21, wherein the polymeric moisture barrier has a thickness from 6.0 to 25.0 micrometers. 
     
     
       23. The blanket of claim 22, wherein the thermoplastic film layer has a thickness no greater than 25 micrometers. 
     
     
       24. The blanket of claim 9, wherein the thermoplastic film layer and the moisture barrier are flame retardant. 
     
     
       25. The blanket of claim 24, wherein the polymeric moisture barrier and the thermoplastic film layer contain polyetheretherketone. 
     
     
       26. The blanket of claim 24, wherein the core is self-extinguishing. 
     
     
       27. A laminate, comprising:
 (i) a polymeric moisture barrier, and   (ii) a carrier free, inorganic platelet layer consisting essentially of platelets of vermiculite.   
     
     
       28. The laminate of claim 27, wherein the moisture barrier contains polymer selected from the group consisting of fluoropolymer, polyimide, polyetheretherketone and polyetherketoneketone. 
     
     
       29. The laminate of claim 27, wherein an outer surface of the moisture barrier is metalized. 
     
     
       30. The laminate of claim 27, wherein the carrier free, inorganic platelet layer consists of platelets of vermiculite. 
     
     
       31. The laminate of claim 27, wherein the platelets have an aspect ratio of from 100 to 20,000. 
     
     
       32. The laminate of claim 31, wherein the platelets have a thickness of from 5 Angstroms to 5,000 Angstroms. 
     
     
       33. The laminate of claim 27, wherein the carrier free, inorganic platelet layer has a thickness from 7.0 to 76.0 micrometers. 
     
     
       34. The laminate of claim 33, wherein the polymeric moisture barrier has a thickness from 6.0 to 25.0 micrometers. 
     
     
       35. The laminate of claim 26, wherein the polymeric moisture barrier is flame retardant. 
     
     
       36. The laminate of claim 35 wherein the polymeric moisture barrier contains polyetheretherketone.