Laminated composites using bonding material from reaction of metal oxide, calcium silicate and phosphoric acid
AssigneeArmstrong World Industries, Inc.
InventorsJeffery L. Barrall, Ronald J. Leib, Debra L. Morris
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Abstract
The present invention relates to laminated materials which are constructed using layers of reinforcing and/or non-reinforcing materials in combination with layers of a composition which is known in the art to provide water-resistant phosphate ceramic materials. In a preferred embodiment, the products are fire-resistant and intumescent when exposed to heat or direct flame, and they produce little or no smoke. Nevertheless, these products are tough, durable and suitable to provide a decorative and pleasing appearance.
Claims38
A bonded composite structure comprising at least one layer of at least one type of layer material, each said layer of layer material being bonded to contiguous layers of layer material by at least one type of water-resistant phosphate bonding material obtained from the reaction of a composition comprising a metal oxide, calcium silicate and phosphoric acid.
A fire-resistant bonded composite comprising
- a plurality of layers of at least one type of layer material, and
- a plurality of layers of at least one type of water-resistant phosphate bonding material obtained from the reaction of a composition comprising a metal oxide, calcium silicate and phosphoric acid, each said layer of layer material being bonded to contiguous layers of layer material by said bonding material, said bonded composite being capable of exhibiting intumescent properties when exposed to flame and/or heat.
A process for forming a bonded composite structure, said process comprising the steps of
- preparing a layered composition comprising
- (a) at least one layer of at least one type of phosphate bonding composition comprising a metal oxide, calcium silicate and phosphoric acid, said composition being suitable to provide a water-resistant phosphate bonding material, and
- (b) at least one layer of at least one type of layer material, said composite being arranged such that contiguous layers of said layer material are in contact with intervening layers of said bonding composition, and
- curing said layered composition, optionally by subjecting it to heat and/or pressure.
Dependencies are inferred from the claim text.