System and method for coating a fire-resistant material on a substrate

Abstract

A method for coating a fire-resistant substance onto a carrier veil and products containing fire-resistant substances are provided. The method includes delivering a pliable carrier veil in a traveling web, drawing the carrier veil web through a reservoir defined by a nip of two rollers and containing the fire-resistant substance, where the carrier veil is coated with the fire-resistant substance. The method also includes controlling the amount of fire-resistant substance on the carrier veil web by setting a nip dimension between the two rollers, passing the carrier veil through the nip of the two rollers and providing the fire-resistant substance as a slurry suitable to coat the veil exiting the nip with a layer effective to provide a selected fire resistance. Heat is applied to the carrier veil sufficient to accelerate a curing reaction in the fire-resistant substance. A fire-resistant product includes a glass-based web, and a magnesium oxychloride complex materially coupled to the web, where the complex includes: MgCl 2 .mMg(OH) 2 .nH 2 O; where m is between about 3 and about 7, and n is between about 6 and about 10.

1 - 32 . (canceled) 
     
     
         33 . A method for providing a cementitious fire-resistant substance onto a substrate comprising the steps of:
 pre-processing a substrate to increase surface area available for bonding with the cementitious fire-resistant substance;   weighing the substrate;   depositing a layer of cementitious fire-resistant substance on the pre-processed substrate in slurry form to initiate a penetrating process of the cementitious fire-resistant substance into the pre-processed substrate;   providing a selected amount of cementitious fire-resistant substance in the slurry form on a pliable carrier veil;   depositing the pliable carrier veil on the substrate, wherein the cementitious fire-resistant substance in slurry form on each of the substrate and the pliable carrier veil blend into a continuous layer; and   determining a fire resistance of the substrate with the deposited pliable carrier veil having a selected amount of cementitious fire-resistant substance per square unit of substrate by weighing the substrate with the pliable carrier veil and comparing its weight with the weight of the substrate.   
     
     
         34 . The method of  claim 33 , wherein the substrate is comprised of cellulosic material, and pre-processing the substrate comprises opening interstitial spaces in the cellulosic material. 
     
     
         35 . The method of  claim 33 , further comprising applying heat to the substrate with the deposited pliable carrier veil to initiate an accelerating curing process of the cementitious fire-resistant substance. 
     
     
         36 . The method of  claim 35 , wherein the amount of heat delivered is measured by measuring a surface temperature of a top surface of the substrate having the deposited pliable carrier veil. 
     
     
         37 . The method of  claim 36 , further comprising comparing the measured surface temperature with a target surface temperature and removing the substrate having the deposited pliable carrier veil from the applied heat upon the top surface reaching the target surface temperature. 
     
     
         38 . The method of  claim 35 , further comprising controlling a temperature of heat, humidity, intensity of heating, air speed or substrate transport speed in connection with applying the heat to initiate the accelerating curing process. 
     
     
         39 . The method of  claim 33 , further comprising controlling the fire resistance of the substrate having the deposited pliable carrier veil thereon by adjusting an amount of cementitious fire resistant substance deposited on the substrate or adjusting the selected amount of cementitious fire-resistant substance provided on the pliable carrier veil. 
     
     
         40 . A method for coating a cementitious fire-resistant substance onto a substrate comprising the steps of:
 providing an amount of a cementitious fire-resistant substance in a slurry form to a pliable carrier veil, wherein the cementitious fire-resistant substance is deposited in and on said pliable carrier veil web to form a veil layer;   depositing a layer of cementitious fire-resistant substance on a substrate in slurry form to initiate a penetrating process of the cementitious fire-resistant substance into the substrate;   delivering the veil layer uncured to the substrate surface such that the substrate and veil layer are coupled by the cementitious fire-resistant substance on the veil layer and the substrate forming a continuous layer;   applying an initial amount of heat to the coupled substrate and veil layer for initiating a curing reaction in the cementitious fire-resistant substance;   removing the accelerating heat to allow the continuous layer of cementitious fire-resistant substance to slow cure to promote a cementitious bond with the substrate surface; and   providing the substrate coated with the veil layer with a selected fire resistance by controlling the amount of said cementitious fire-resistant substance deposited in and on said pliable carrier veil, controlling a rate at which said slurry form of cementitious fire-resistant substance is deposited on the substrate, controlling a rate at which the uncured veil layer is delivered to the substrate, controlling a rate of transport of the substrate as the substrate and the veil layer are coupled, or controlling a period of time the initial amount of heat is applied to the coupled substrate and veil layer.   
     
     
         41 . The method of  claim 40 , wherein the selected fire resistance is provided by sensing a parameter of the cementitious fire-resistant substance affecting a cure rate of the cementitious fire-resistant substance and adjusting one or more of the controlled rates or amount of time based on the sensed parameter. 
     
     
         42 . The method of  claim 40 , wherein the selected fire resistance is provided by sensing ambient conditions, and in response, adjusting one or more of the controlled rates or amount of time. 
     
     
         43 . A product comprising a substrate and a cementitious fire-resistant substance provided thereon, the product produced by the process comprising the steps of:
 forming a nip between two rollers;   supplying to the nip a pliable carrier veil in a traveling web having a selected thickness;   supplying said cementitious fire-resistant substance to the nip in slurry form, to form a reservoir of said cementitious fire-resistant substance defined by said nip of two rollers;   controlling the amount of said cementitious fire-resistant substance impregnated in and on said pliable carrier veil, wherein controlling comprises setting a nip dimension between said two rollers according to the selected pliable carrier veil thickness such that the two rollers exert a pressure on the pliable carrier veil that determines an amount of the cementitious fire-resistant substance passing with said pliable carrier veil through said nip of the two rollers and impregnate the pliable carrier veil exiting the nip to form a veil layer effective to provide a selected fire resistance;   delivering the veil layer uncured to a surface of the substrate by advancing the substrate and veil layer at the same rate such that the veil layer and substrate are coupled in a continuous feed by gravity and slurry surface tension of uncured cementitious fire-resistant substance in the veil, without positive pressure on the veil layer during such coupling;   applying an initial amount of thermal treatment to the impregnated veil layer sufficient to accelerate a curing reaction in the cementitious fire-resistant substance; and   removing the accelerating thermal treatment after a predefined period to control water loss from the veil layer and allow the cementitious fire-resistant substance to slow cure to promote a cementitious bond with the substrate surface.   
     
     
         44 . The product according to  claim 43 , further produced by the steps comprising:
 coating a first layer of a cementitious fire-resistant substance on the substrate; and   wherein the step of delivering the veil layer comprises depositing said veil layer uncured as a second layer over the uncured first layer of cementitious fire-resistant material, said first and second layers undergoing the accelerating heat and slow cure together.