Fire protected elastomeric insulation
View Patent ↗The present invention relates to a versatile multi-layer elastomer or thermoplastic elastomer based thermal and/or sound insulation material with improved fire retardant properties together with low smoke generation, the process for manufacturing of such material and the use of such material and resulting composites.
1. A material comprising an elastomer or thermoplastic elastomer being expanded to a density of less than 200 kg/m 3 according to ISO 845 as a core (C) being covered with at least one inner protective layer (B) comprising a metal foil showing a thickness of 1-400 microns, or fibrous material which is at least flame retardant according to DIN 4102 B1 and/or ASTM E-84 flame spread 100 and outer protective layer (A) consisting of fibrous material which is at least flame retardant according to DIN 4102 B1 and/or ASTM E-84 flame spread 100 and wherein, if (A) and (B) are both of fibrous nature, the ratio of average mesh or sieve opening of (A) to (B) is bigger than 1:1, wherein the outer protective layer (A) is the outermost layer of said material, wherein the closed cell content of the expanded core (C) is at least 80%.
2. The material according to claim 1 wherein the metal foil of (B) is aluminium.
3. The material according to claim 1 wherein the fibrous material of (A) and/or (B) is in the form of a weave fabric, knitted fabric, unidirectional weave or nonwoven.
4. The material according to claim 1 wherein the fibrous material of (A) and/or (B) is embedded to at least 30 weight percent into a matrix, preferably into a fire retardant and/or non flammable and/or halogenated material, especially preferred into CPE and/or PVC and/or silicate based adhesive.
5. The material according to claim 3 wherein the fibrous material of (A) and/or (B) is glass fibre.
6. The material according to claim 1 wherein the fibrous material of (A) shows an average mesh size or sieve opening of 0.01 to 2.00 mm and has average thread or fibre density of 5 to 500 per cm.
7. The material according to claim 1 wherein the fibrous material of (B) shows an average mesh or sieve opening size for the tissue of 0.01 to 0.80 mm and has average thread or fibre density of 5 to 250 per cm.
8. The material according to claim 1 wherein at least the layers (A) and (B) are bonded with a flame retardant and/or non flammable compound, preferably a flame retardant and/or non flammable adhesive.
9. The material according to claim 8 wherein the flame retardant and/or non flammable compound is pre-applied on layer (B) or between layers (A) and (B) before final lamination onto (C).
10. The material according to claim 8 wherein the flame retardant and/or non flammable compound is based on halogen containing and/or silicate compounds.
11. The material according to claim 1 wherein additional layers are applied for protection, reinforcement and decoration purposes.
12. The material according to claim 1 wherein the layers except (A) to (B) are bonded by the use of an adhesive and/or hot melt and/or thermoplastic.
13. The material according to claim 12 , wherein the adhesive and/or hot melt and/or thermoplastic is already pre-applied on at least one side of layer (B) or between and/or on top of at least one side of layers (A) and (B) before final lamination onto (C).
14. The material according to claim 13 comprising a prefabricated composite of at least layers (A) and (B), and wherein said prefabricated composite is applied with an adhesive and/or hot melt and/or thermoplastic on one or more sides of (C).
15. The material according to claim 1 , wherein layer (A) and/or layer (B) form one or more overlaps that can be used to form butt joint seals and/or seam seals between multilayer parts of at least (A)(B)(C) configuration and/or between said multilayer parts and other materials.
16. The material according to claim 1 , wherein surface structures are applied on the inner and/or outer side of the (A)(B)(C) composite to improve sound/thermal decoupling, adhesion and flame/heat dispersion.
17. The material according to claim 1 wherein the whole composite is showing a water vapour diffusion barrier property of at least μ 2500 according to EN 12086.
18. The material according to claim 1 wherein the whole composite has a thermal conductivity of less than 0.080 W/m*K at 0° C. according to EN 12667.
19. A process for manufacturing the material according to claim 1 in a continuous process.
20. The process for manufacturing the material according to claim 19 in a continuous two-step-extrusion/expansion and lamination process.
21. The process for manufacturing the material according to claim 19 where a prefabricated composite of at least (A) and (B) is laminated onto (C).
22. A method of providing thermal insulation and/or sound insulation and/or vibration damping insulation and/or fire protection insulation, comprising affixing the material of claim 1 to the inside or outside of structures, vessels, containers and/or pipes.
23. The method of claim 22 , wherein said material is affixed to walls, ceilings, floors, roofs, tanks, tubes, and ducts.