Fibrous composite materials and the production and use thereof

Abstract

A fibrous composite material in the form of individual fibres, sheets, layers or lightweight blocks comprising non-combustible fibres and lamellae of a layer mineral, a method for the manufacture of the fibrous composite materials by applying lamellae of a layer mineral to the fibres preferably from suspension followed by removal of the liquid phase of the suspension, and use of the fibrous composite materials for the fire-protection of substrates.

We claim: .[.1. A fibrous composite material consisting essentially of at least 15% by weight non-combustible fibers, and at least 20% by weight lamallae of chemically delaminated vermiculite, the lamallae having a thickness of less than 0.5 micron and an aspect ratio of at least 10, the 
     
        fibers being bonded together by the vermiculite..]. .[.2.  A fibrous composite material as claimed in claim 1 wherein said fibres are present in the amount of at least 20% by weight..]. .[.3. A material as claimed in claim 1 wherein the fibres are glass fibres..]. .[.4. A material as claimed in claim 1 wherein the loading of the layer mineral is up to 100% 
     
     
        by weight based on the fibres..]. 5. .[.A material as claimed in claim 1.]. .Iadd.A fibrous composite material consisting essentially of at least 15% by weight non-combustible continuous or staple length fibres, and at least 20% by weight lamellae of chemically delaminated vermiculite, the lamellae having a thickness of less than 0.5 micron and an aspect ratio of at least 100, the fibres being bonded together solely by the vermiculite, .Iaddend.wherein the vermiculite lamellae .[.are substantially all of.]. .Iadd.consist of particles having a .Iaddend.maximum dimension below 50 
     
     
        microns. 6. A material as claimed in claim .[.1.]. .Iadd.5 .Iaddend.wherein the fibres are present in the form of a layer of fibrous 
     
     
        material. 7. A material as claimed in claim .[.1.]. .Iadd.5 .Iaddend.in the form of a block of randomly oriented fibres bonded together at their 
     
     
        points of contact by the vermiculite. 8. A material as claimed in claim 7 
     
     
        wherein the fibres are coated with said vermiculite. .[.9.  A material as claimed in claim 1 which additionally contains a water-stability improver..]. .[.10. A material as claimed in claim 9 wherein the water 
     
     
        stability improver is magnesium oxide..]. 11. A material as claimed in claim .[.1.]. .Iadd.5 .Iaddend.wherein the chemically delaminated vermiculite is present in the form of a dry, rigid foam 
     
     
        .Iadd.matrix.Iaddend.. .[.12.  A material as claimed in claim 1 in which the vermiculite lamallae thickness is less than 0.05 micron..]. .[.13. A material as claimed in claim 12 in which the vermiculite lamallae thickness is less than 0.1005 micron..]. .[.14. A material as claimed in claim 1 in which the vermiculite lamallae have an aspect ratio of at least 100..]. .[.15. A material as claimed in claim 14 in which the vermiculite lamallae have an aspect ratio of at least 1000..]. .[.16. A material as claimed in claim 1 in which the vermiculite lamallae are less than 0.005 
     
     
        micron thick and have an aspect ratio of at least 1000..]. .Iadd.17.  A material as claimed in any one of claims 5, 6 or 7 wherein said non-combustible fibres consist essentially of glass fibres. .Iaddend.