US4710309A
Expired / Lapsed
US
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Lightweight soundproofing, insulation and fireproofing material and method
Assignee: AMERICAN SPRAYED-ON FIBERS Inc A CORP INDIANA
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Filing: 1986-12-04
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Granted: 1987-12-01
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Expires: 2006-12-04
Abstract
Abstract A lightweight soundproofing, insulation and fireproofing material and method is disclosed. A dry composition is provided which includes 60-80% by weight of an inorganic lightweight nonflammable fibrous material, 16.67-36.67% by weight of an organic lightweight normally-flammable fibrous material, and 3.33-10% by weight of a refracted clay material. The non-flammable fibrous material is pulled apart to provide a high temperature loose fiber material, the normally-flammable fibrous material is shredded, and the refracted clay material is embedded in the normally-flammable fibrous material after shredding to reduce the flammability thereof. Thereafter, the nonflammable fibrous material is mixed with the normally-flammable fibrous material to complete the dry composition. A liquid adhesive is provided which includes liquid sodium silicate having a ratio of silicon dioxide to sodium oxide that is greater than 3.22:1, the liquid sodium silicate in the form of a solution of about 50% water is mixed with water in a ratio of approximately 1:1, and a surfactant can be added to the liquid sodium silicate to act as a wetting agent for application and flexibility purposes. With these constituent components, the liquid adhesive is used with the dry composition at the rate of approximately 55 gallons of liquid adhesive for each 300 lbs. of dry composition.
Inventors
- 👤 Dennis C. Miller
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 19:53
CPC Classifications
C; C04; C04B; C04B28/00; C04B28/24; C04B28/26; C04B2111/00; C04B2111/00474; C04B2111/00482; C04B2111/20; C04B2111/28; C04B2111/52; Y; Y02; Y02W; Y02W30/00; Y02W30/50; Y02W30/91
Claims Analysis
Total Claims: 43
Claim 1
Independent Claim
50 words
A dry composition for use with a liquid adhesive to form a soundproofing, insulating and fireproofing material, comprising: about 60-80% by weight of an inorganic lightweight nonflammable fibrous material; about 16.67-36.67% by weight of an organic lightweight normally-flammable fibrous material; and about 3.33-10% by weight of a refracted clay material.
Claim 2
Dependent Claim
50 words
A dry composition for use with a liquid adhesive to form a soundproofing, insulating and fireproofing material, comprising: about 60-80% by weight of an inorganic lightweight nonflammable fibrous material; about 16.67-36.67% by weight of an organic lightweight normally-flammable fibrous material; and about 3.33-10% by weight of a refracted clay material.
Claim 3
Dependent Claim
23 words
The composition as defined by claim 1 wherein said liquid adhesive includes liquid sodium silicate for retaining said dry composition on a surface.
Claim 4
Dependent Claim
23 words
The composition as defined by claim 1 wherein said nonflammable fibrous material includes mineral wool and said normally-flammable fibrous material includes cellulose fiber.
Claim 5
Dependent Claim
17 words
The composition as defined by claim 3 wherein shredded paper is utilized to provide said cellulose fiber.
Claim 6
Dependent Claim
20 words
The composition as defined by claim 4 including about 90-96.67% by weight of said mineral wool and said shredded paper.
Claim 7
Dependent Claim
20 words
The composition as defined by claim 1 wherein said nonflammable fibrous material consists of a high temperature loose fiber material.
Claim 8
Dependent Claim
35 words
The composition as defined by claim 1 wherein said refracted clay material has been fired at or above a temperature of approximately 3300° F. so as to have a melting point of approximately 2750° F.
Claim 9
Dependent Claim
34 words
The composition as defined by claim 7 wherein said refracted clay material is in the form of particles and has a bulk density of about 30 lbs. per cubic foot plus or minus 5%.
Claim 10
Dependent Claim
21 words
The composition as defined by claim 8 wherein said particles of refracted clay material are embedded in said normally-flammable fibrous material.
Claim 11
Dependent Claim
94 words
A lightweight soundproofing, insulation and fireproofing material, comprising: a dry composition including: about 60-80% by weight of an inorganic lightweight nonflammable fibrous material; about 16.67-36.67% by weight of an organic lightweight normally-flammable fibrous material; and about 3.33-10% by weight of a refracted clay material; said refracted clay material reducing the flammability of said normally-flammable fibrous material; and a liquid adhesive including: liquid sodium silicate having a ratio of silicon dioxide to sodium oxide that is greater than 3.22:1; said liquid adhesive being adapted retain said dry composition on a surface in a fireproof manner.
Claim 12
Dependent Claim
94 words
A lightweight soundproofing, insulation and fireproofing material, comprising: a dry composition including: about 60-80% by weight of an inorganic lightweight nonflammable fibrous material; about 16.67-36.67% by weight of an organic lightweight normally-flammable fibrous material; and about 3.33-10% by weight of a refracted clay material; said refracted clay material reducing the flammability of said normally-flammable fibrous material; and a liquid adhesive including: liquid sodium silicate having a ratio of silicon dioxide to sodium oxide that is greater than 3.22:1; said liquid adhesive being adapted retain said dry composition on a surface in a fireproof manner.
Claim 13
Dependent Claim
23 words
The material as defined by claim 10 wherein said non-flammable fibrous material includes mineral wool and said normally-flammable fibrous material includes cellulose fiber.
Claim 14
Dependent Claim
17 words
The material as defined by claim 11 wherein shredded paper is utilized to provide said cellulose fiber.
Claim 15
Dependent Claim
20 words
The material as defined by claim 12 including about 90-96.67% by weight of said mineral wool and said shredded paper.
Claim 16
Dependent Claim
35 words
The material as defined by claim 10 wherein said refracted clay material has been fired at or above a temperature of approximately 3300° F. so as to have a melting point of approximately 2750° F.
Claim 17
Dependent Claim
34 words
The material as defined by claim 14 wherein said refracted clay material is in the form of particles and has a bulk density of about 30 lbs. per cubic foot plus or minus 5%.
Claim 18
Dependent Claim
21 words
The material as defined by claim 15 wherein said particles of refracted clay material are embedded in said normally-flammable fibrous material.
Claim 19
Dependent Claim
20 words
The material as defined by claim 10 wherein said nonflammable fibrous material consists of a high temperature loose fiber material.
Claim 20
Dependent Claim
30 words
The material as defined by claim 10 wherein said liquid sodium silicate is a solution of about 50% water thereafter further mixed with water in a ratio of approximately 1:1.
Claim 21
Dependent Claim
34 words
The material as defined by claim 18 wherein said liquid adhesive is used with said dry composition at the rate of approximately 55 gallons of liquid adhesive for each 300 pounds of dry composition.
Claim 22
Dependent Claim
21 words
The material as defined by claim 10 including a surfactant in said liquid sodium silicate to act as a wetting agent.
Claim 23
Dependent Claim
25 words
The material as defined by claim 20 wherein said surfactant is an anionic sulfonated alkyl ester comprising about 0.5% by weight of said liquid adhesive.
Claim 24
Independent Claim
140 words
A method of making a dry composition for use with a liquid adhesive for forming a soundproofing, insulating and insulation fireproofing material, comprising the steps of: providing about 16.67-36.67% by weight of an organic lightweight normally-flammable fibrous material; shredding said normally-flammable fibrous material; providing about 3.33-10% by weight of a refracted clay material; embedding said refracted clay material in said normally-flammable fibrous material after shredding to reduce the flammability thereof; providing about 60-80% by weight of an inorganic lightweight nonflammable fibrous material; pulling said nonflammable fibrous material apart to provide a high temperature loose fiber material; and mixing said nonflammable fibrous material with said normally-flammable fibrous material; said nonflammable fibrous material being mixed with said normally-flammable fibrous material after said refracted clay material has been embedded in said normally-flammable fibrous material and said nonflammable fibrous material has been pulled apart.
Claim 25
Independent Claim
140 words
A method of making a dry composition for use with a liquid adhesive for forming a soundproofing, insulating and insulation fireproofing material, comprising the steps of: providing about 16.67-36.67% by weight of an organic lightweight normally-flammable fibrous material; shredding said normally-flammable fibrous material; providing about 3.33-10% by weight of a refracted clay material; embedding said refracted clay material in said normally-flammable fibrous material after shredding to reduce the flammability thereof; providing about 60-80% by weight of an inorganic lightweight nonflammable fibrous material; pulling said nonflammable fibrous material apart to provide a high temperature loose fiber material; and mixing said nonflammable fibrous material with said normally-flammable fibrous material; said nonflammable fibrous material being mixed with said normally-flammable fibrous material after said refracted clay material has been embedded in said normally-flammable fibrous material and said nonflammable fibrous material has been pulled apart.
Claim 26
Dependent Claim
23 words
The method as defined by claim 22 wherein said nonflammable fibrous material includes mineral wool and said normally-flammable fibrous material includes cellulose fiber.
Claim 27
Dependent Claim
17 words
The method as defined by claim 23 wherein shredded paper is utilized to provide said cellulose fiber.
Claim 28
Dependent Claim
20 words
The method as defined by claim 24 including about 90-96.67% by weight of said mineral wool and said shredded paper.
Claim 29
Dependent Claim
35 words
The method as defined by claim 22 wherein said refracted clay material has been fired at or above a temperature of approximately 3300° F. so as to have a melting point of approximately 2750° F.
Claim 30
Dependent Claim
34 words
The method as defined by claim 26 wherein said refracted clay material is in the form of particles and has a bulk density of about 30 lbs. per cubic foot plus or minus 5%.
Claim 31
Dependent Claim
20 words
The method as defined by claim 27 wherein said particles of refracted clay are embedded in said normally-flammable fibrous material.
Claim 32
Independent Claim
175 words
A method of making a lightweight soundproofing, insulating and fireproofing material, comprising the steps of: providing a dry composition by: providing about 16.67-36.67% by weight of an organic lightweight normally-flammable fibrous material; shredding said normally-flammable fibrous material; providing about 3.33-10% by weight of a refracted clay material; embedding said refracted clay material in said normally-flammable fibrous material after shredding to reduce the flammability thereof; providing about 60-80% by weight of an inorganic lightweight non-flammable fibrous material; pulling said non-flammable fibrous material apart to provide a high temperature loose fiber material; and mixing said non-flammable fibrous material with said normally-flammable fibrous material; said non-flammable fibrous material being mixed with said normally-flammable fibrous material after said refracted clay material has been embedded in said nonflammable fibrous material and said nonflammable fibrous material has been pulled apart; and providing a liquid adhesive by: providing liquid sodium silicate having a ratio of silicon dioxide to sodium oxide that is greater than 3.22:1; said liquid adhesive being adapted to retain said dry composition on a surface in a fireproof manner.
Claim 33
Independent Claim
175 words
A method of making a lightweight soundproofing, insulating and fireproofing material, comprising the steps of: providing a dry composition by: providing about 16.67-36.67% by weight of an organic lightweight normally-flammable fibrous material; shredding said normally-flammable fibrous material; providing about 3.33-10% by weight of a refracted clay material; embedding said refracted clay material in said normally-flammable fibrous material after shredding to reduce the flammability thereof; providing about 60-80% by weight of an inorganic lightweight non-flammable fibrous material; pulling said non-flammable fibrous material apart to provide a high temperature loose fiber material; and mixing said non-flammable fibrous material with said normally-flammable fibrous material; said non-flammable fibrous material being mixed with said normally-flammable fibrous material after said refracted clay material has been embedded in said nonflammable fibrous material and said nonflammable fibrous material has been pulled apart; and providing a liquid adhesive by: providing liquid sodium silicate having a ratio of silicon dioxide to sodium oxide that is greater than 3.22:1; said liquid adhesive being adapted to retain said dry composition on a surface in a fireproof manner.
Claim 34
Dependent Claim
30 words
The method as defined by claim 29 wherein said liquid sodium silicate is a solution of about 50% water thereafter further mixed with water in a ratio of approximately 1:1.
Claim 35
Dependent Claim
34 words
The method as defined by claim 30 wherein said liquid adhesive is used with said dry composition at the rate of approximately 55 gallons of liquid adhesive for each 300 lbs. of dry composition.
Claim 36
Dependent Claim
23 words
The method as defined by claim 29 wherein a surfactant is added to said liquid sodium silicate to act as a wetting agent.
Claim 37
Dependent Claim
25 words
The method as defined by claim 32 wherein said surfactant is an anionic sulfonated alkyl ester comprising about 0.5% by weight of said liquid adhesive.
Claim 38
Dependent Claim
23 words
The method as defined by claim 29 wherein said nonflammable fibrous material includes mineral wool and said normally-flammable fibrous material includes cellulose fiber.
Claim 39
Dependent Claim
17 words
The method as defined by claim 34 wherein shredded paper is utilized to provide said cellulose fiber.
Claim 40
Dependent Claim
19 words
The method as defined by claim 35 including about 90-96.67% by weight of mineral wool and said shredded paper.
Claim 41
Dependent Claim
35 words
The method as defined by claim 29 wherein said refracted clay material has been fired at or above a temperature of approximately 3300° F. so as to have a melting point of approximately 2750° F.
Claim 42
Dependent Claim
34 words
The method as defined by claim 37 wherein said refracted clay material is in the form of particles and has a bulk density of about 30 lbs. per cubic foot plus or minus 5%.
Claim 43
Dependent Claim
21 words
The method as defined by claim 38 wherein said particles of refracted clay material are embedded in said normally-flammable fibrous material.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1990-11-30 | 1991-06-01 | 1991-12-01 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1994-11-30 | 1995-06-01 | 1995-12-01 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1998-11-30 | 1999-06-01 | 1999-12-01 | $7700.00 | Window Closed / Lapsed |