IP Library › Granted Patent US 7,563,733
Granted Patent B2
US 7,563,733 · App. 10/766,678 · Granted Jul 21, 2009

Composite material

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Quick Facts
Patent No.
US 7,563,733
App. No.
10/766,678
Granted
Jul 21, 2009
Kind
B2
Abstract

A composite material comprising a first layer which comprises a surfactant component, surfactant-generated microcells, a gel catalyst component and a binder component, and a second layer which comprises a metallic component is provided. The first layer may further comprise a filler component. In addition, the composite material may further comprise a substrate to which the first layer is adhered. The composite materials have heat insulating and fire resistant characteristics and are particularly suited for use in building materials and mattresses.

Claims (22)

1. A heat insulating and fire resistant composite material consisting essentially of:

(a) a first layer which comprises a surfactant component, surfactant-generated microcells, a gel catalyst component selected from the group consisting of a thermosetting gel catalyst, a vulcanizing gel catalyst, a cross-linking gel catalyst and combinations thereof and a binder component; and

(b) a second layer comprising a metallic component adhered to the first layer.

2. The composite material according to claim 1 wherein the first layer further comprises a filler component.

3. The composite material according to claim 2 wherein the filler comprises clay.

4. A heat insulating and fire resistant composite material comprising:

(a) a substrate

(b) a first layer adhered to the substrate to provide a coated substrate, said first layer comprising a surfactant component, surfactant-generated microcells, a gel catalyst component selected from the group consisting of a thermosetting gel catalyst, a vulcanizing gel catalyst, a cross-linking gel catalyst and combinations thereof, a filler component comprising clay and binder component and a binder component, wherein said binder component bonds the filler material together and to the substrate and wherein said first layer does not bleed through the substrate; and

(c) a second layer comprising a metallic component adhered to the coated substrate.

5. The composite material according to claim 4 wherein said substrate is planar and said first layer is adhered to one side of the substrate.

6. The composite material according to claim 4 wherein said substrate is planar and said first layer is adhered to both sides of the substrate.

7. The composite according to claim 5 or 6 wherein said second layer is adhered to one side of said coated substrate.

8. The composite according to claim 5 or 6 wherein said second layer is adhered to both sides of said coated substrate.

9. The composite material according to claim 1 or 4 further comprising a water repellant material.

10. The composite material according to claim 1 or 4 further comprising an antifungal material.

11. The composite material according to claim 1 or 4 further comprising an antibacterial material.

12. The composite material according to claim 1 or 4 further comprising a surface friction agent.

13. The composite material according to claim 1 or 4 further comprising a flame retardant material.

14. The composite material according to claim 1 or 4 further comprising an algaecide.

15. The composite material according to claim 1 or 4 further comprising a dye.

16. The composite material according to claim 1 or 4 , wherein the metallic component is selected from the group consisting of aluminum or stainless steel.

17. The composite material according to claim 16 wherein the metallic component is aluminum foil.

Assignments (6)
SECURITY INTEREST Recorded Sep 23, 2021
From: BMIC LLC; ELKCORP; ELK COMPOSITE BUILDING PRODUCTS, INC.; ELK PREMIUM BUILDING PRODUCTS, INC.; HBP ACQUISITION LLC; GAF ENERGY LLC; SIPLAST, INC.; SPECIALTY GRANULES INVESTMENTS LLC
To: DEUTSCHE BANK AG NEW YORK BRANCH
Reel/Frame 057572/0607 →
RELEASE OF SECURITY INTEREST Recorded Nov 5, 2011
From: DEUTSCHE BANK TRUST COMPANY AMERICAS, AS COLLATERAL AGENT
To: ELKCORP; ELK PREMIUM BUILDING PRODUCTS, INC.; ELK CORPORATION OF AMERICA; ELK CORPORATION OF ALABAMA; ELK CORPORATION OF TEXAS; ELK CORPORATION OF ARKANSAS; ELK PERFORMANCE NONWOVEN FABRICS, INC.; ELK COMPOSITE BUILDING PRODUCTS, INC.; RGM PRODUCTS, INC.; RIDGEMATE MANUFACTURING CO., INC.; ELK SLATE PRODUCTS, INC.; ELK VERSASHIELD BUILDING SOLUTIONS, INC.; ELK TECHNOLOGY GROUP, INC.; CHROMIUM CORPORATION; ELK TECHNOLOGIES, INC.; MIDLAND PATH FORWARD, INC.; LUFKIN PATH FORWARD, INC.; ELK GROUP, INC.; ELK GROUP, L.P.; NELPA, INC.
Reel/Frame 027180/0400 →
RELEASE OF SECURITY INTEREST Recorded Nov 5, 2011
From: DEUTSCHE BANK AG NEW YORK BRANCH, AS COLLATERAL AGENT
To: ELKCORP; ELK PREMIUM BUILDING PRODUCTS, INC.; ELK CORPORATION OF AMERICA; ELK CORPORATION OF ALABAMA; ELK CORPORATION OF TEXAS; ELK CORPORATION OF ARKANSAS; ELK PERFORMANCE NONWOVEN FABRICS, INC.; ELK COMPOSITE BUILDING PRODUCTS, INC.; RGM PRODUCTS, INC.; RIDGEMATE MANUFACTURING CO., INC.; ELK SLATE PRODUCTS, INC.; ELK VERSASHIELD BUILDING SOLUTIONS, INC.; ELK TECHNOLOGY GROUP, INC.; CHROMIUM CORPORATION; ELK TECHNOLOGIES, INC.; MIDLAND PATH FORWARD, INC.; LUFKIN PATH FORWARD, INC.; ELK GROUP, INC.; ELK GROUP, L.P.; NELPA, INC.
Reel/Frame 027180/0435 →
SECURITY AGREEMENT Recorded Jun 22, 2007
From: ELKCORP; ELK PREMIUM BUILDING PRODUCTS, INC.; ELK CORPORATION OF AMERICA; ELK CORPORATION OF ALABAMA; ELK CORPORATION OF TEXAS; ELK CORPORATION OF ARKANSAS; ELK COMPOSITE BUILDING PRODUCTS, INC.; RGM PRODUCTS, INC.; RIDGEMATE MANUFACTURING CO. INC.; ELK SLATE PRODUCTS, INC.; ELK VERSASHIELD BUILDING SOLUTIONS, INC.; ELK TECHNOLOGY GROUP, INC.; CHROMIUM CORPORATION; ELK TECHNOLOGIES, INC.; MIDLAND PATH FORWARD, INC.; LUFKIN PATH FORWARD, INC.; ELK GROUP, INC.; ELK GROUP, LP; NELPA, INC.; ELK PERFORMANCE NONWOVEN FABRICS, INC.
To: DEUTSCHE BANK TRUST COMPANY AMERICAS
Reel/Frame 019466/0247 →
SECURITY AGREEMENT Recorded Jun 22, 2007
From: ELKCORP; ELK PREMIUM BUILDING PRODUCTS, INC.; ELK CORPORATION OF AMERICA; ELK CORPORATION OF ALABAMA; ELK CORPORATION OF TEXAS; ELK CORPORATION OF ARKANSAS; ELK PERFORMANCE NONWOVEN FABRICS, INC.; ELK COMPOSITE BUILDING PRODUCTS, INC.; RGM PRODUCTS, INC.; RIDGEMATE MANUFACTURING CO. INC.; ELK SLATE PRODUCTS, INC.; ELK VERSASHIELD BUILDING SOLUTIONS, INC.; ELK TECHNOLOGY GROUP, INC.; CHROMIUM CORPORATION; ELK TECHNOLOGIES, INC.; MIDLAND PATH FORWARD, INC.; LUFKIN PATH FORWARD, INC.; ELK GROUP, INC.; ELK GROUP, LP; NELPA, INC.
To: DEUTSCHE BANK AG NEW YORK BRANCH
Reel/Frame 019466/0270 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jul 14, 2004
From: AHLUWALIA, YOUNGER; KIIK, MATTI; KAROL, THOMAS D.
To: ELKCORP
Reel/Frame 015563/0981 →