Fire Proofing Composition

The following examples are provided for illustrative purposes only and are in no way intended to limit the scope of the present invention.

A composition containing the following ingredients was prepared:

exfoliated vermiculite 168 g

silica: 14 g

clay: 14 g

mica: 28 g

biotite: 28 g

Elmer's aliphatic resin: 56 g

C.M.A. adhesive: 28 g

water: 28 g

The exfoliated vermiculite, clay and silica and mica, i.e., the dry materials, were processed to obtain a uniform grain size of 0.15 to 0.25 mm.

The Elmer's aliphatic resin and C.M.A. adhesive were mixed in a separate container at room temperature until a thick consistency was obtained. The dry minerals were then added to the liquid, a small portion at a time, at room temperature to insure complete mixing of the ingredients.

The clay was obtained from the Contee Sand and Gravel Pit in Beltsville, Md. and has a yellowish brown color.

The composition was applied to the following substrates: red oak, white pine, aluminum foil, galvanized sheet metal, a 1" steel beam, a galvanized wire screen, an aluminum sheet, 4" polyurethane, 2" blue polyboard, 1" styrofoam, 1/4" standard gypsum board, 3/8" wall panel wood and cardboard covered wall boards, in a thickness of about 1/32 to 1/8 of an inch.

The combustibility and heat testing was conducted using a propane below torch having a temperature of 2400.degree. to 3200.degree. F. The torch was applied for 30 seconds to 5 minutes to the substrate coated with the composition of the present invention.

Using the red oak and white pine wood, the fire test revealed that when the blow torch flame was applied to untreated pieces thereof, the wood immediately started to burn whereas, on wood treated with the composition of the present invention, which was torched with the flame 3 to 5 inches from the treated surface, the treated surface changed from grayish brown to a dark black-brown but no burning was observed.

When the blow torch flame was applied to an untreated piece of aluminum foil, the foil disintegrated instantaneously whereas, when the blow torch was applied to aluminum foil treated with the composition of the present invention, there was no change in the character of the foil. Similar results were obtained using the other substrates described above.

A composition containing the following ingredients was prepared:

exfoliated vermiculite: 168 g

silica: 14 g

clay (Contee): 14 g

mica: 28 g

biotite: 28 g

Elmer's aliphatic resin: 56 g

water: 28 g

The above dry materials were processed to obtain a uniform grain size of 0.15 to 0.25 mm. Next, the Elmer's aliphatic resin was applied to the surface of an aluminum foil or sheet. The resin was either sprayed on or brushed on. Next, the mixture of exfoliated vermiculite, silica, mica and biotite and clay was applied with an air spray tool on the wet adhesive and allowed to dry. Drying too, about 2-6 hours. The dry thickness was about 0.79 mm. The results obtained were identical to Example 1, i.e., the treated foil or sheet did not burn even when exposed to the blow torch for 30 seconds to 1 minute.

A composition containing the following ingredients was prepared:

exfoliated vermiculite: 28 g

silica: 14 g

clay (Contee): 14 g

mica: 28 g

biotite: 28 g

L.G.H. liquid hide glue: 28 g

Elmer's aliphatic resin: 56 g

C.M.A. adhesive: 28 g

The biotite, exfoliated vermiculite, silica, clay and mica minerals were processed to a grain size of 0.15 to 0.25 mm and mixed in one container.

In a separate container, L.G.H. liquid hide glue, Elmer's aliphatic resin and C.M.A. adhesive were mixed at room temperature. Then, the contents in the two containers were mixed together at room temperature to obtain the composition of the present invention. The composition was applied to white pine, dry red oak, a steel rod (1" by 1/8"), polyurethane foam, and galvanized sheet metal, by means of a trowel.

The composition of the present invention was applied in thicknesses of about 1/8" on the above-identified substrates allowed to dry for 8 hours and then subjected to propane blow torch as described above. The results demonstrated that with all of the substrates treated with the composition of the present invention, no burning was seen when the blow torch was applied for 1 to 5 minutes.

A composition containing the following ingredients was prepared:

exfoliated vermiculite: 168 g

silica: 14 g

clay (Contee): 14 g

mica: 28 g

biotite: 28 g

Elmer's aliphatic resin: 56 g

plaster of Paris: 80 g

water: 28 g

The above materials were processed in the same manner as Example 1 and applied, in the thickness of 1/8" to 1", to a galvanized wire screen by emersion coating, and dried for about 4 to 6 hours. The results obtained were identical to Example 1, i.e., the treated galvanized wire did not burn when exposed to the blow torch for 1 to 15 minutes.

Compositions containing the following ingredients, where only the particular type of clay employed was varied, were prepared:

exfoliated vermiculite: 168 g

silica: 14 g

clay shown in Table 1: 14 g

mica: 28 g

biotite: 28 g

Basf Corp. Acronal 290D Dispersion: 56 g

C.M.A. adhesive: 28 g

water: 28 g

The materials were processed in the same manner as in Example 1 and applied, in a thickness of 1/4" to white pine board and dried for about 24 hours. Then the coated boards were heated to 1832.degree. to 2192.degree. F. with an air-gas torch. All of the treated boards did not burn when exposed to the air-gas torch for 30 minutes, i.e., charring occurred but the coating provided protection by inhibiting the engress of oxygen to the surface of the wood. Further, although charring occurred, the integrity of the wood was maintained. In addition, no major differences were observed as to the amount of char under the coatings regardless of which clay was employed in the composition. This demonstrates that substitution of various clays does not effect the fire retardant properties of the composition.

Compositions containing the following ingredients, where the type of adhesive employed was varied, were prepared:

The materials were processed in the same manner as in Example 1 and applied, in a thickness of 1/4" to white pine board and dried for about 24 hours. Then the coated boards were heated to 1832.degree. to 2192.degree. F. with an air-gas torch. All of the treated boards did not burn when exposed to the air-gas torch for 30 minutes, i.e., charring occurred but the coating provided protection by inhibiting the engress of oxygen to the surface of the wood. Further, although charring occurred, the integrity of the wood was maintained. In addition, no major differences were observed as to the amount of char under the coatings regardless of which adhesive was employed in the composition. This demonstrates that substitution of various adhesives does not effect the fire retardant properties of the composition. These compositions also provided excellent water resistant properties and thus are advantageous when employed in high moisture environments.

The invention has been described with reference to specific embodiments thereof. However, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.