Flame resistant fibrous insulation and methods of making the same

Abstract

The invention relates to fibrous insulation products that exhibit improved flame resistance, relative to previously known products. The insulation product has a fibrous mineral matrix, into which is incorporated a phosphate-containing compound (e.g., an inorganic phosphate salt) and a refractory mineral filler (e.g., alumina or aluminum sulfate). The product exhibits flame resistance superior to the fibrous mineral matrix alone.

1 . A flame resistant insulation product comprising a fibrous mineral combined with a phosphate-containing compound and a non-silicate refractory mineral filler.  
     
     
         2 . The insulation product of  claim 1 , wherein the fibrous mineral is glass wool.  
     
     
         3 . The insulation product of  claim 2 , wherein the diameter of the glass wool fibers is in the range from about 0.5 to 20 micrometers.  
     
     
         4 . The insulation product of  claim 1 , wherein the phosphate-containing compound is an inorganic phosphate salt.  
     
     
         5 . The insulation product of  claim 4 , wherein the inorganic phosphate salt is selected from the group consisting of monoanrnonium phosphate, diammonium phosphate, ammonium polyphosphate, monocalcium phosphate, dicalcium phosphate, aluminum phosphate, monosodium dihydrogen phosphate, tetrasodium pyrophosphate, sodium hexametaphosphate, sodium tripolyphosphate, tetrapotassium pyrophosphate, and potassium tripolyphosphate.  
     
     
         6 . The insulation product of  claim 4 , wherein the inorganic phosphate salt is selected from the group consisting of monoammonium phosphate and diammonium phosphate.  
     
     
         7 . The insulation product of  claim 4 , wherein the inorganic phosphate salt is monoammonium phosphate.  
     
     
         8 . The insulation product of  claim 1 , wherein the refractory mineral filler is in a particulate form.  
     
     
         9 . The insulation product of  claim 1 , wherein the refractory mineral filler is selected from the group consisting of alumina, calcium oxide, magnesium oxide, titanium oxide, zirconia, and aluminum sulfate.  
     
     
         10 . The insulation product of  claim 1 , wherein the refractory mineral filler is selected from the group consisting of alumina and aluminum sulfate.  
     
     
         11 . The insulation product of  claim 1 , wherein the phosphate-containing compound is monoammonium phosphate and the refractory mineral filler is alumina.  
     
     
         12 . The insulation product of  claim 11 , wherein the monoammonium phosphate and the alumina are present in approximately equal amounts by weight.  
     
     
         13 . The insulation product of  claim 12 , wherein the combined weight of the monoammonium phosphate and the alumina is at least about 6% the weight of the insulation product.  
     
     
         14 . The insulation product of  claim 12 , wherein the combined weight of the monoammonium phosphate and the alumina is at least about 11% the weight of the insulation product.  
     
     
         15 . The insulation product of  claim 1 , wherein the phosphate-containing compound is monoammonium phosphate and the refractory mineral filler is aluminum sulfate.  
     
     
         16 - 18 . (canceled)  
     
     
         19 . The insulation product of  claim 1 , wherein the phosphate-containing compound and the refractory mineral filler are present in a binding composition that comprises an adhesive for binding the fibrous material.  
     
     
         20 - 21 . (canceled)  
     
     
         22 . The insulation product of  claim 1 , wherein the fibrous mineral is in the form of a shaped article.  
     
     
         23 - 29 . (canceled)  
     
     
         30 . A method of making a flame resistant insulation product, the method comprising combining a phosphate-containing compound and a non-silicate refractory mineral filler with a fibrous mineral matrix.  
     
     
         31 - 35 . (canceled)  
     
     
         36 . A method of improving the flame resistance of a fibrous mineral insulation product, the method comprising incorporating a phosphate-containing compound and a non-silicate refractory mineral filler into the insulation product.  
     
     
         37 - 39 . (canceled)  
     
     
         40 . A method of improving the flame resistance of a structure, the method comprising incorporating the insulation product of  claim 1  in the structure.  
     
     
         41 - 43 . (canceled)