High temperature thermo-acoustic barrier material with low smoke and odor
A thermal barrier material is disclosed for applications such as heat shields in automobiles and other vehicles. The thermal barrier material is made on a Fordenier paper making machine from a slurry that is very low in organic compounds that can cause smoke and odor when exposed to high temperatures. A first thermal barrier material is disclosed that can withstand up to 650° C. and a second thermal barrier material is disclosed that can withstand up to 1000° C. In each case, the barrier material withstands it max temperature specification while producing extremely low quantities of smoke and extremely low levels of offensive odors. Prior art thermal barrier materials with similar temperature specifications on the other hand produce many times the smoke and offensive odors at the same temperatures and do so for a far longer time.
1. A thermal barrier material for use in shielding components of a vehicle from hot surfaces comprising:
17 to 23% magnesium silicate by weight;
2 to 5% aluminum phyllosilicate clay by weight;
17 to 23% hydrous aluminum silicate by weight;
12 to 18% hydrous magnesium silicate by weight;
4 to 7% phyllosilicate by weight;
17 to 23% aluminum trihydrate by weight;
2 to 6% alumino-borosilicate glass by weight;
6 to 8% rock wool by weight;
1 to 6% basalt fibers by weight;
0.05 to 1.5% acrylamide copolymer coagulant by weight;
0.07 to 1.2% acrylic latex by weight;
0.01 to 0.05% fatty alcohol alkoxylate by weight; and
0.5 to 1.5% anionic polyacrylamide by weight.
2. The thermal barrier material of claim 1 , wherein
a sample of the thermal barrier material, when exposed to a temperature of 400° Centigrade, produces smoke having a density less than 5 g/cm 3 as measured according to the ISO 5659-2:2006(E) standard.
3. The thermal barrier material of claim 1 , wherein
a sample of the thermal barrier material, when exposed to a temperature of 400° Centigrade, produces smoke having a density less than 2 g/cm 3 as measured according to the ISO 5659-2:2006(E) standard.
4. The thermal barrier material of claim 1 , wherein
a sample of the thermal barrier material, when exposed to a temperature of 400° Centigrade, produces smoke having a density of about 0.88 g/cm 3 as measured according to the ISO 5659-2:2006(E) standard.
5. The thermal barrier material of claim 1 , wherein
a sample of the thermal barrier material produces less than 4 ppm of 1-butanal gas as measured by Gas Chromatography (GC) and Mass Spectrometry (MS).
6. The thermal barrier material of claim 1 , wherein
a sample of the thermal barrier material produces no detected 1-butanal gas as measured by Gas Chromatography (GC) and Mass Spectrometry (MS).
7. The thermal barrier material of claim 1 , wherein
a sample of the thermal barrier material produces less than 150 ppm Dimethoxymethane gas as measured by Gas Chromatography (GC) and Mass Spectrometry (MS).
8. The thermal barrier material of claim 1 , wherein
a sample of the thermal barrier material produces about 55 ppm Dimethoxymethane gas as measured by Gas Chromatography (GC) and Mass Spectrometry (MS).
9. The thermal barrier material of claim 1 , wherein
a sample of the thermal barrier material does not ignite when exposed to a temperature of 650° Centigrade in a furnace.
10. A thermal barrier material for use in shielding components of a vehicle from hot surfaces, comprising:
8 to 12% magnesium silicate by weight;
2 to 5% aluminum phyllosilicate clay by weight;
8 to 12% hydrous aluminum silicate by weight;
12 to 18% hydrous magnesium silicate by weight;
4 to 7% phyllosilicate by weight;
35 to 43% aluminum trihydrate by weight;
2 to 6% alumino-borosilicate glass by weight;
6 to 8.5% rock wool by weight;
4 to 7% basalt fibers by weight;
0.05 to 1.5% acrylamide copolymer coagulant by weight;
0.05 to 0.95% acrylic latex by weight;
0.01 to 0.05% fatty alcohol alkoxylate by weight; and
0.5 to 1.5% anionic polyacrylamide by weight.
11. The thermal barrier material of claim 10 , wherein
a sample of the thermal barrier material, when exposed to a temperature of 400° Centigrade, produces smoke having a density less than 5 g/cm 3 as measured according to the ISO 5659-2:2006(E) standard.
12. The thermal barrier material of claim 10 , wherein
a sample of the thermal barrier material, when exposed to a temperature of 400° Centigrade, produces smoke having a density less than 2 g/cm 3 as measured according to the ISO 5659-2:2006(E) standard.
13. The thermal barrier material of claim 10 , wherein
a sample of the thermal barrier material, when exposed to a temperature of 400° Centigrade, produces smoke having a density of about 0.88 g/cm 3 as measured according to the ISO 5659-2:2006(E) standard.
14. The thermal barrier material of claim 10 , wherein
a sample of the thermal barrier material produces less than 4 ppm of 1-butanal gas as measured by Gas Chromatography (GC) and Mass Spectrometry (MS).
15. The thermal barrier material of claim 10 , wherein
a sample of the thermal barrier material produces no detected 1-butanal gas as measured by Gas Chromatography (GC) and Mass Spectrometry (MS).
16. The thermal barrier material of claim 10 , wherein
a sample of the thermal barrier material produces less than 150 ppm Dimethoxymethane gas as measured by Gas Chromatography (GC) and Mass Spectrometry (MS).
17. The thermal barrier material of claim 10 , wherein
a sample of the thermal barrier material produces about 42.6 ppm Dimethoxymethane gas as measured by Gas Chromatography (GC) and Mass Spectrometry (MS).
18. The thermal barrier material of claim 10 , wherein
a sample of the thermal barrier material produces less than 100 ppm CO gas as measured according to ASTM 800 standards.
19. The thermal barrier material of claim 10 , wherein
a sample of the thermal barrier material produces about 46 ppm CO gas as measured according to ASTM 800 standards.
20. The thermal barrier material of claim 10 , wherein
a sample of the thermal barrier material produces less than 700 ppm CO2 gas as measured according to ASTM 800 standards.
21. The thermal barrier material of claim 10 , wherein
a sample of the thermal barrier material produces about 599 ppm CO2 gas as measured according to ASTM 800 standards.
22. The thermal barrier material of claim 10 , wherein
a sample of the thermal barrier material does not ignite when exposed to a temperature of 650° Centigrade in a furnace.