MULTILAYERED SHEET
This invention pertains to a layered sheet structure comprising a carrier having a first and second surface, a metalized layer contacting one of the surfaces of the carrier and an inorganic refractory layer contacting the surface of the metalized layer not in contact with the carrier. The refractory layer has a dry area weight of from 15 to 50 gsm and a residual moisture content of no greater than 10 percent by weight. The carrier is a polymeric film, preferably polyethyleneterephthalate.
1 . A layered sheet structure comprising a carrier having a first and second surface, a metalized layer contacting one of the surfaces of the carrier and an inorganic refractory layer contacting the surface of the metalized layer not in contact with the carrier wherein the refractory layer has a dry areal weight of from 15 to 50 gsm and a residual moisture content of no greater than 10 percent by weight, wherein the carrier
(i) is a polymeric film,
(ii) has a dry tensile strength of at least 10 lb/in in a first direction and at least 5 lb/in in a second direction, the second direction being transverse to the first direction,
(iii) has a thickness of from 0.012 to 0.100 mm,
(iv) has a density of from 0.9 to 1.8 g/cc, and
(v) is thermally stable at a temperature of at least 150 degrees C. for at least 10 minutes.
2 . The layered sheet of claim 1 wherein the surface value of the metalized surface of the carrier that is in contact with the refractory layer is from 0.005 to 0.25 lb/in.
3 . The layered sheet of claim 1 wherein the inorganic refractory layer comprises vermiculite.
4 . The layered sheet of claim 1 wherein the polymeric film is thermoplastic.
5 . The layered sheet of claim 1 wherein the metalized layer is aluminum.
6 . The layered sheet of claim 1 wherein the carrier is a metallic foil or a metallic belt.
7 . The layered sheet of claim 1 wherein the layered structure, when wetted, has shrinkage no greater than 2 percent.
8 . The layered sheet of claim 1 wherein the refractory layer has a dry areal weight of from 20 to 35 gsm.
9 . The layered structure of claim 1 wherein the film has a tensile strength of at least 30 lb/in in a first direction and at least 15 lb/in in a second direction, the second direction being transverse to the first direction.
10 . The layered structure of claim 1 wherein the polymeric film has a thickness of from 0.025 to 0.100 mm (1-4 mil).
11 . The layered structure of claim 1 wherein the polymeric film has a thickness of from 0.038 to 0.075 mm (1.5 to 3 mil),
12 . The layered structure of claim 1 wherein a smoothness on the metalized surface of the film contacting the intumescent layer is no greater than 80 Sheffield units.
13 . The layered structure of claim 1 wherein a smoothness on the metalized surface of the film contacting the intumescent layer is no greater than 30 Sheffield units.
14 . The layered structure of claim 2 wherein the refractory layer has a residual moisture content of no greater than 3 percent by weight.
15 . The refractory layer of claim 2 wherein the layer further comprises cations.