Flame-resistant insulation

Abstract

Flame-resistant insulation may be prepared by coating a glass fiber substrate, such as a fiberglass board, with an aqueous dispersion of vermiculite and expandable graphite. The insulation may also be pre-coated with a vermiculite dispersion prior to coating with a vermiculite/expandable graphite coating, and the vermiculite/expandable graphite coating may be covered with an FSK facing, or with a gypsum or portland cement layer. The resulting coated insulation board has superior flame resistance, and may be used as a component of a building or in vehicles.

What is claimed as new and is intended to be secured by Letters Patent is:  
     
         1 . Flame and heat-resistant insulation comprising a glass fiber substrate coated with a mixture comprising vermiculite and expandable graphite.  
     
     
         2 . The flame and heat-resistant insulation of  claim 1 , wherein the weight ratio of vermiculite to expandable graphite in the coating is in the range of 10:1 to 1:10.  
     
     
         3 . The flame and heat-resistant insulation of  claim 1 , wherein the mixture further comprises an organic binder.  
     
     
         4 . The flame and heat-resistant insulation of  claim 1 , wherein the mixture further comprises an inorganic binder.  
     
     
         5 . The flame and heat-resistant insulation of  claim 1 , wherein the coating has a dry weight of 5 to 30 g/100 in 2 .  
     
     
         6 . The flame and heat-resistant insulation of  claim 1 , wherein the coating has a dry weight of 10 to 30 g/100 in 2 .  
     
     
         7 . The flame and heat-resistant insulation of  claim 1 , wherein an FSK facing is adhered to the coating.  
     
     
         8 . The flame and heat-resistant insulation of  claim 1 , wherein a cement layer is deposited on the coating.  
     
     
         9 . The flame and heat-resistant insulation of  claim 1 , wherein a gypsum layer is deposited on the coating.  
     
     
         10 . The flame and heat-resistant insulation of  claim 1 , wherein said glass fiber substrate is selected from the group consisting of a glass fiber flexible mat, a glass fiber fabric, a glass fiber sheet, and a glass fiber board.  
     
     
         11 . The flame and heat-resistant insulation of  claim 10 , wherein the glass fiber substrate is a glass fiber board.  
     
     
         12 . The flame and heat-resistant insulation of  claim 11 , wherein the board has a density of 2.5 to 6 lb/ft 3 .  
     
     
         13 . A method of preparing the flame and heat-resistant insulation of  claim 1 , wherein a mixture comprising vermiculite and expandable graphite are dispersed in water, said dispersion is coated onto a glass fiber substrate, and dried.  
     
     
         14 . The method of  claim 13 , wherein said depositing is selected from the group consisting of spraying, roller coating, gravure coating, curtain coating, slot-die coating and brushing.  
     
     
         15 . A door panel comprising the flame and heat-resistant insulation of  claim 1 .  
     
     
         16 . A wall comprising the flame and heat-resistant insulation of  claim 1 .  
     
     
         17 . A building insulation comprising the flame and heat-resistant insulation of  claim 1 .  
     
     
         18 . A vehicle insulation comprising the flame and heat-resistant insulation of  claim 1.