Composite flame barrier laminate for a thermal and acoustic insulation blanket

Abstract

A multilayer laminate comprising a first polymeric film layer capable of withstanding a temperature of at least 200 C for at least 10 min, a first adhesive layer having an areal weight of from 2 to 40 gsm capable of activation at a temperature of from 75 to 200 degrees C., an inorganic refractory layer comprising platelets in an amount of at least 85% by weight with a dry areal weight of 15 to 50 gsm and having a residual moisture content of no greater than 10 percent by weight, a second adhesive layer having an areal weight of from 4 to 40 gsm capable of activation at a temperature of from 75 to 200 degrees C. and a second polymeric film layer capable of withstanding a temperature of at least 200 C for at least 10 minutes.

What is claimed is: 
     
         1 . A multilayer laminate for use as a flame barrier comprising 
       (i) a first polymeric film layer capable of withstanding a temperature of at least 200 C for at least 10 min, 
       (ii) a first adhesive layer having an areal weight of from 2 to 40 gsm and having an activation temperature of from 75 to 200 degrees C., 
       (iii) an unsupported inorganic refractory layer having a dry areal weight of 15 to 50 gsm and a residual moisture content of no greater than 10 percent by weight, 
       (iv) a second adhesive layer having an areal weight of from 2 to 40 gsm and having an activation temperature of from 75 to 200 degrees C., and 
       (v) a second polymeric film layer capable of withstanding a temperature of at least 200 C for at least 10 min, 
       wherein
 (a) at least one of the first or second polymeric film layers is thermoplastic, and 
 (b) at least 85% by weight of the unsupported inorganic refractory layer comprises vermiculite platelets. 
 
     
     
         2 . The laminate of  claim 1  wherein the inorganic refractory layer is perforated. 
     
     
         3 . The laminate of  claim 1  wherein the first or second polymeric film layer is a fluoropolymer, polyimide, polyetheretherketone, or polyetherketoneketone. 
     
     
         4 . The laminate of  claim 1  wherein the first and/or second polymeric film layer is metalized on at least one surface. 
     
     
         5 . The laminate of  claim 1  wherein either the first or second or both adhesive layers optionally contain up to 40 weight percent of a flame retardant ingredient. 
     
     
         6 . The laminate of  claim 1  wherein the adhesive bond between the inorganic refractory layer and the first polymeric film is at least 0.5 lb/in. 
     
     
         7 . The laminate of  claim 1  wherein the adhesive bond between the inorganic refractory layer and the second polymeric film is at least 0.25 lb/in. 
     
     
         8 . The laminate of  claim 1  wherein the inorganic refractory layer has a dry areal weight of from 20 to 35 gsm. 
     
     
         9 . The laminate of  claim 1  wherein the inorganic refractory layer has a moisture content of no greater than 3%. 
     
     
         10 . The laminate of  claim 2  wherein the adhesive bond between inorganic refractory layer and either polymeric film is at least 1.0 lb/in. 
     
     
         11 . The laminate of  claim 6  wherein the adhesion bond between the inorganic refractory layer and the first polymeric film is at least 0.8 lb/in. 
     
     
         12 . The laminate of  claim 7  wherein the adhesion bond between the inorganic refractory layer and the second polymeric film is at least 0.8 lb/in. 
     
     
         13 . The laminate of  claim 10  wherein the adhesion bond between inorganic refractory layer and either polymeric film is at least 1.5 lb/in. 
     
     
         14 . A flame barrier layer in a vehicle or building structure comprising the multilayer laminate of  claim 1 . 
     
     
         15 . A thermal acoustic blanket for an aircraft comprising the flame barrier of  claim 14 . 
     
     
         16 . A cargo liner for an aircraft comprising the flame barrier layer of  claim 14 .