US4569878A
Expired / Lapsed
US
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Laminated composites using bonding material from reaction of metal oxide, calcium silicate and phosphoric acid
Assignee: Armstrong World Industries Inc
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Filing: 1985-03-22
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Granted: 1986-02-11
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Expires: 2005-03-22
Abstract
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.
Inventors
- 👤 Jeffery L. Barrall
- 👤 Ronald J. Leib
- 👤 Debra L. Morris
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 11:34
CPC Classifications
B; B32; B32B; B32B7/00; B32B7/04; B32B7/12; E; E04; E04B; E04B1/00; E04B1/62; E04B1/92; E04B1/94; Y; Y10; Y10S; Y10S428/00; Y10S428/92; Y10S428/921; Y10T; Y10T428/00; Y10T428/24; Y10T428/24149; Y10T428/24628; Y10T428/24669; Y10T428/24694; Y10T428/24711; Y10T428/24727; Y10T428/24802; Y10T428/2481; Y10T428/249921; Y10T428/249953; Y10T428/249982; Y10T428/249984; Y10T428/26; Y10T428/263; Y10T428/31504; Y10T428/31971; Y10T428/31993; Y10T442/00; Y10T442/10; Y10T442/102; Y10T442/133; Y10T442/14; Y10T442/147; Y10T442/30; Y10T442/3472; Y10T442/3602; Y10T442/3699; Y10T442/60; Y10T442/659; Y10T442/67
Claims Analysis
Total Claims: 41
Claim 1
Independent Claim
57 words
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.
Claim 2
Dependent Claim
57 words
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.
Claim 3
Dependent Claim
33 words
The structure as set forth in claim 1 hereof wherein said metal oxide is selected from the group consisting of aluminum oxide, magnesium oxide, calcium oxide and zinc oxide, and the hydrates thereof.
Claim 4
Dependent Claim
20 words
The structure as set forth in claim 2 hereof wherein said bonding composition comprises a substantially uniform layer of material.
Claim 5
Dependent Claim
20 words
The structure as set forth in claim 2 hereof wherein said bonding composition comprises a substantially discontinuous layer of material.
Claim 6
Dependent Claim
19 words
The structure as set forth in claim 2 hereof wherein said bonded composite comprises a synthetic mica layer material.
Claim 7
Dependent Claim
24 words
The structure as set forth in claim 2 hereof wherein said bonded composite comprises a woven, a non-woven or a chopped glass layer material.
Claim 8
Dependent Claim
24 words
The structure as set forth in claim 2 hereof wherein said bonded composite comprises a woven, a non-woven or a chopped synthetic layer material.
Claim 9
Dependent Claim
19 words
The structure as set forth in claim 2 hereof wherein said bonded composite comprises a kraft paper layer material.
Claim 10
Dependent Claim
19 words
The structure as set forth in claim 2 hereof wherein said bonded composite comprises a wire mesh layer material.
Claim 11
Dependent Claim
17 words
The structure as set forth in claim 1 hereof wherein said bonding composition comprises aluminum oxide trihydrate.
Claim 12
Dependent Claim
16 words
The structure as set forth in claim 1 hereof wherein said bonding composition comprises magnesium oxide.
Claim 13
Dependent Claim
33 words
The structure as set forth in claim 1 hereof wherein said structure comprises a non-planar reinforcing layer comprising at least one type of layer material and at least one type of bonding material.
Claim 14
Dependent Claim
81 words
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.
Claim 15
Dependent Claim
81 words
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.
Claim 16
Dependent Claim
33 words
The composite as set forth in claim 13 hereof wherein said metal oxide is selected from the group consisting of aluminum oxide, magnesium oxide, calcium oxide and zinc oxide, and the hydrates thereof.
Claim 17
Dependent Claim
20 words
The composite as set forth in claim 14 hereof wherein said bonding composition comprises a substantially continuous layer of material.
Claim 18
Dependent Claim
20 words
The composite as set forth in claim 14 hereof wherein said bonding composition comprises a substantially discontinuous layer of material.
Claim 19
Dependent Claim
19 words
The composite as set forth in claim 14 hereof wherein said bonded composite comprises a synthetic mica layer material.
Claim 20
Dependent Claim
24 words
The composite as set forth in claim 14 hereof wherein said bonded composite comprises a woven, a non-woven or a chopped glass layer material.
Claim 21
Dependent Claim
24 words
The composite as set forth in claim 14 hereof wherein said bonded composite comprises a woven, a non-woven or a chopped synthetic layer material.
Claim 22
Dependent Claim
19 words
The composite as set forth in claim 14 hereof wherein said bonded composite comprises a kraft paper layer material.
Claim 23
Dependent Claim
19 words
The composite as set forth in claim 14 hereof wherein said bonded composite comprises a wire mesh layer material.
Claim 24
Dependent Claim
17 words
The composite as set forth in claim 13 hereof wherein said bonding composition comprises aluminum oxide trihydrate.
Claim 25
Dependent Claim
16 words
The composite as set forth in claim 13 hereof wherein said bonding composition comprises magnesium oxide.
Claim 26
Dependent Claim
24 words
The composite as set forth in claim 13 hereof wherein said composite comprises at least one non-planar reinforcing layer comprising at least one material.
Claim 27
Dependent Claim
102 words
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.
Claim 28
Dependent Claim
102 words
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.
Claim 29
Dependent Claim
33 words
The process as set forth in claim 25 hereof wherein said metal oxide is selected from the group consisting of aluminum oxide, magnesium oxide, calcium oxide and zinc oxide, and the hydrates thereof.
Claim 30
Dependent Claim
23 words
The process as set forth in claim 26 hereof wherein at least one of said layer materials is a synthetic mica layer material.
Claim 31
Dependent Claim
28 words
The process as set forth in claim 26 hereof wherein at least one of said layer materials is a woven, a non-woven or a chopped glass layer material.
Claim 32
Dependent Claim
28 words
The process as set forth in claim 26 hereof wherein at least one of said layer materials is a woven, a non-woven or a chopped synthetic layer material.
Claim 33
Dependent Claim
23 words
The process as set forth in claim 26 hereof wherein at least one of said layer materials is a kraft paper layer material.
Claim 34
Dependent Claim
23 words
The process as set forth in claim 26 hereof wherein at least one of said layer materials is a wire mesh layer material.
Claim 35
Dependent Claim
17 words
The process as set forth in claim 25 hereof wherein said bonding composition comprises aluminum oxide trihydrate.
Claim 36
Dependent Claim
16 words
The process as set forth in claim 25 hereof wherein said bonding composition comprises magnesium oxide.
Claim 37
Dependent Claim
26 words
The process as set forth in claim 25 hereof wherein said bonding composition is applied at a thickness of from about 1 to about 20 mils.
Claim 38
Dependent Claim
20 words
The process as set forth in claim 25 hereof wherein said bonding composition is applied as a mechanically frothed foam.
Claim 39
Dependent Claim
22 words
The process as set forth in claim 25 hereof wherein said bonding composition is applied as a substantially continuous layer of material.
Claim 40
Dependent Claim
22 words
The process as set forth in claim 25 hereof wherein said bonding composition is applied as a substantially discontinuous layer of material.
Claim 41
Dependent Claim
40 words
The process as set forth in claim 25 hereof wherein at least one layer of said layer material comprises a preformed, non-planar reinforcing layer comprising at least one type of layer material and at least one type of bonding material.
References Cited (Backward Citations)
US4375516A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1989-02-10 | 1989-08-12 | 1990-02-11 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-02-10 | 1993-08-12 | 1994-02-11 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1997-02-10 | 1997-08-12 | 1998-02-11 | $7700.00 | Window Closed / Lapsed |