# US 12,595,418 B2 · Fiber-containing fire protection material

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- Number: US 12,595,418 B2
- Document ID: US12595418B2
- Status: Granted
- Kind: B2
- Application number: 18/181,801
- Filed: 2023-03-10
- Published: 2023-08-24
- Granted: 2026-04-07
- Earliest claimed: 2022-02-24
- Assignees: Unifrax I LLC
- Applicants: Unifrax I LLC
- Inventors: Andrew Bodratti; Jonathan Cross; Alexander J. Manly; Trevor West
- Web page: https://patentgrep.com/patent/US12595418B2

## CPC

- C09K 21/02: Inorganic materials
- H01M 50/271: Lids or covers for the racks or secondary casings
- C09D 7/61: inorganic
- C09D 183/04: Polysiloxanes
- C09K 21/06: Organic materials
- C09K 21/14: Macromolecular materials
- H01M 4/13: Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
- H01M 10/0525: Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
- H01M 10/658: by thermal insulation or shielding
- H01M 50/117: Inorganic material
- H01M 50/143: Fireproof; Explosion-proof
- H01M 50/204: Racks, modules or packs for multiple batteries or multiple cells
- H01M 50/209: adapted for prismatic or rectangular cells (H01M50/216 takes precedence)
- H01M 50/24: adapted for protecting batteries from their environment, e.g. from corrosion (thermal insulation H01M10/658)
- H01M 50/293: characterised by the material
- C08L 83/04: Polysiloxanes
- H01M 2200/00: Safety devices for primary or secondary batteries
- H01M 2220/20: Batteries in motive systems, e.g. vehicle, ship, plane
- Y02E 60/10: Energy storage using batteries
- C09K: MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

A fire protection material includes at least 10 wt % of inorganic fibers, at least 5 wt % of an additive dispersed within the inorganic fibers, the additive selected from fibers, particles, platelets, aerogels, a foam, or combinations thereof; and at least 2 wt % of a binder dispersed within the inorganic fibers. The inorganic fibers, additive, and binder account for at least 60 wt % of the fire protection material.

## Claims

### Claim 1

A fire protection material comprising:
at least 10 wt % of inorganic fibers;
at least 5 wt % of a particulate additive dispersed within the inorganic fibers, the particulate additive selected from precipitated silica, silicon carbide, or combinations thereof; and
at least 2 wt % of a binder dispersed within the inorganic fibers;
wherein the inorganic fibers, the particulate additive, and the binder account for at least 60 wt % of the fire protection material;
wherein the fire protection material does not comprise platelets.

### Claim 2 (depends on 1)

The fire protection material of claim 1, wherein the inorganic fibers comprise refractory ceramic fiber (RCF), low bio-persistent (LBP) fiber, alkaline earth silicate (AES) fiber, polycrystalline wool (PCW), or a combination thereof.

### Claim 3 (depends on 1)

The fire protection material of claim 1, wherein the particulate additive comprises the precipitated silica at 5 to 60 wt %.

### Claim 4 (depends on 1)

The fire protection material of claim 1, wherein the binder comprises latex, cellulose, silicones, polyvinyl alcohol, organic fibers, or a combination thereof.

### Claim 5 (depends on 4)

The fire protection material of claim 4, comprising 5 to 15 wt % of the binder.

### Claim 6 (depends on 4)

The fire protection material of claim 4, wherein the binder comprises organic fibers that are dispersed within the inorganic fibers and heated to bind the fire protection material.

### Claim 7 (depends on 1)

The fire protection material of claim 1, further comprising 2 to 40 wt % of a compressive additive selected from polyurethane, polyethylene, ethylene propylene diene monomer (EPDM), polyethylene terephthalate (PET), silicone, acrylic latex, organic fibers, or combinations thereof dispersed within the inorganic fibers.

### Claim 8 (depends on 1)

A fire protection article comprising:
the fire protection material of claim 1; and
a coating layer disposed on at least one surface of the fire protection material;
wherein the coating layer comprises bentonite clay, dispersible Al2O3, a cross-linkable silicone, or combinations thereof.

### Claim 9 (depends on 8)

The fire protection article of claim 8, wherein the coating layer comprises a polysiloxane and an additive selected from aluminum trihydroxide, magnesium hydroxide, CaCO3, expandable vermiculite, a fluxing agent, inorganic fibers, wollastonite, mica, aerogels, or combinations thereof.

### Claim 10 (depends on 9)

The fire protection article of claim 9, wherein the coating layer comprises the fluxing agent and inorganic fibers.

### Claim 11 (depends on 9)

The fire protection article of claim 9, wherein the coating layer is configured to be ceramized at temperatures of 650° C. or greater.

### Claim 12 (depends on 9)

The fire protection article of claim 9, wherein the coating layer comprises the cross-linkable silicone and is cured using heat or ultraviolet radiation.

### Claim 13 (depends on 8)

A lithium-ion battery comprising:
a housing comprising a lid;
a plurality of cells contained within the housing; and
the fire protection article of claim 8 disposed between at least two of the plurality of cells or between the plurality of cells and the lid.

### Claim 14 (depends on 1)

A fire protection article comprising:
a first layer of the fire protection material of claim 1; and
a compressive layer laminated to the first layer of the fire protection material;
wherein the compressive layer comprises polyurethane, polyethylene, ethylene propylene diene monomer (EPDM), polyethylene terephthalate (PET), silicone, acrylic latex, organic fibers, or combinations thereof; and
wherein the compressive layer does not comprise inorganic fibers.

### Claim 15 (depends on 14)

The fire protection article of claim 14, further comprises a second layer of the fire protection material laminated to the compressive layer opposite the first layer of the fire protection material.

### Claim 16 (depends on 14)

The fire protection article of claim 14, further comprising a coating layer disposed on at least one surface of the first layer of the fire protection material, wherein the coating layer comprises bentonite clay, dispersible Al2O3, a cross-linkable silicone, or combinations thereof.

### Claim 17 (depends on 16)

The fire protection article of claim 16, wherein the coating layer comprises the fluxing agent and inorganic fibers.

### Claim 18 (depends on 14)

A lithium-ion battery comprising:
a housing comprising a lid;
a plurality of cells contained within the housing; and
the fire protection article of claim 14 disposed between at least two of the plurality of cells or between the plurality of cells and the lid.

### Claim 19 (depends on 1)

A lithium-ion battery comprising:
a housing comprising a lid;
a plurality of cells contained within the housing; and
the fire protection material of claim 1 disposed between at least two of the plurality of cells or between the plurality of cells and the lid.

### Claim 20

A fire protection material comprising:
at least 60 wt % of inorganic fibers;
at least 5 wt % of an additive dispersed within the inorganic fibers, the additive selected from particles, platelets, aerogels, a foam, or combinations thereof; and
at least 2 wt % of a binder dispersed within the inorganic fibers.

### Claim 21

A fire protection material comprising:
at least 40 wt % of inorganic fibers;
at least 30 wt % of a particulate additive dispersed within the inorganic fibers, the particulate additive selected from precipitated silica, silicon carbide, or combinations thereof;
at least 10 wt % of a compressive additive dispersed within the inorganic fibers, the compressive additive selected from polyurethane, polyethylene, ethylene propylene diene monomer (EPDM), polyethylene terephthalate (PET), silicone, acrylic latex, organic fibers, or combinations thereof; and
at least 2 wt % of a binder dispersed within the inorganic fibers.